C409 Series

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Controllable diaphragm pump
C/CS 409.2
Operating instructions
2 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

C/CS 409.2
Table of contents
Q. Quickstart�� 6
Q.1 Power connection�� 6
Q.2 Control elements�� 7
Q.3 LED operation indicators�� 7
Q.4 Key operation�� 8
Q.5 Factory settings�� 8
Q.6 Control inputs and outputs�� 9
Q.6.1 Control via contact signal�� 9
Q.6.2 Control via analog signal�� 9
Q.7 Selecting the operating mode�� 10
1. General�� 11
1.1 General user information�� 11
1.2 Symbols and notes used in these operating instructions�� 11
1.3 Notes attached to the product�� 11
1.4 Quality instructions�� 12
2. Safety instructions�� 12
2.1 Personnel qualification and training�� 12
2.2 Dangers in case of inobservance of the safety instructions�� 12
2.3 Safety conscious working�� 12
2.4 Safety instructions for owner / operator�� 13
2.5 Safety instructions for maintenance, servicing and installation work�� 13
2.6 Arbitrary modification and production of spare parts�� 13
2.7 Improper operations�� 13
2.8 Intended use�� 13
2.9 Operating conditions�� 14
2.10 Personal protection for maintenance and service�� 14
2.11 Utilities/Lubricants�� 14
2.11 Foreseeable misuse�� 15
2.11.1 Transport�� 15
2.11.2 Assembly and installation�� 15
2.11.3 Start-up�� 15
2.11.4 Operation�� 16
2.11.5 Maintenance / Repair�� 16
2.11.6 Cleaning�� 16
2.12.7 Shut-down�� 17
2.12.8 Disassembly�� 17
2.12.9 Disposal�� 17
3. Transport and storage�� 18
3.1 General�� 18
3.2 Storage�� 18
4. Product description�� 19
4.1 Types�� 19
4.1.1 Type key�� 19
4.1.2 Type plate�� 20
4.2 Materials�� 20
4.3 Viscosity, pumped medium�� 20
4.4 Dosing range�� 20
4.5 Noise measurement�� 20
4.6 Components of the diaphragm pump�� 21
4.6.1 C409.2�� 21
4.6.2 CS409.2�� 22
4.7 Functional description�� 23
4.7.1 General�� 23
4.7.2 Stroke length adjustment�� 23
4.7.3 Drive motor�� 23
4.7.4 Stroke length adjustment�� 24
4.7.5 Assembly pump�� 27
TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 3

C/CS 409.2
4.7.6 Pump body�� 27
4.7.7 Pump body with integrated overflow valve�� 27
4.7.8 Suction / Pressure valve�� 28
4.7.9 Electronics (operating panel)�� 28
4.7.10 Diaphragm rupture monitoring device (option)�� 29
4.7.11 Manual vent valve (only FRP-execution C 409.2-0,8e - …-2,4e)�� 29
4.7.12 Automatic ventilation device (CS-design)�� 30
5. Technical data�� 31
5.1 Performance data�� 31
5.2 Motor data�� 32
5.3 Additional data for electronics�� 32
5.4 Dimensions�� 33
5.4.1 C 409.2�� 33
5.4.2 CS 409.2�� 38
6. Assembly / Installation�� 41
6.1 Provide overpressure protection�� 43
6.2 Prevent a backflow of the pumped medium�� 44
6.3 Eliminate undesired siphoning�� 45
6.4 How to ensure an gas-free suction�� 45
6.5 Install the empty-tank alarm�� 46
6.6 How to avoid an emptying of the suction line�� 46
6.7 Line strainer�� 47
6.8 Suction via a siphon pipe�� 47
6.9 In case of slightly degassing dosing media�� 48
6.10 Dosing of suspensions�� 48
6.11 Damping of the pulsation�� 49
7. Electrical connections�� 51
7.1 Electric supply�� 51
7.2 Electrical interfaces�� 52
7.2.1 Control inputs and outputs�� 52
7.2.2 Level input with pre-alarm and dry run�� 54
7.2.3 Input for flow control and flow meter�� 55
8. Operation in non-hazardous areas�� 55
9. Start-Up�� 56
9.1 Driving Motor�� 56
9.2 Initial start / Restart�� 56
10. Operation�� 57
10.1 Operating elements�� 57
10.2 LED operation indicators�� 57
10.3 Key operation�� 58
10.4 Parameter table�� 59
10.5 Menu�� 61
10.5.1 Screen “Operating messages”�� 61
10.5.2 Fault and warning messages�� 62
10.5.3 Screen “Main menu”�� 63
10.5.4 Value entry�� 63
10.5.5 Menu guide�� 65
10.6 Selecting the operation mode�� 70
10.7 Additional settings for the operation mode�� 71
10.7.1 Additional settings for the ANALOG operation mode�� 71
10.7.2 Additional settings for the PULSE mode�� 75
10.7.3 Additional settings for the BATCH mode�� 76
10.7.4 Settings for the EXTERNAL operation mode�� 78
10.8 Configuring the inputs and outputs�� 78
10.8.1 Digital input 01�� 79
10.8.2 Digital/analog inputs 02 and 03�� 80
10.8.3 Outputs 01 and 02�� 80
10.9 Flow rate indicator�� 81
10.10 Calibration�� 83

C/CS 409.2
10.11 System�� 85
10.12 Totalizer�� 85
10.13 Password�� 85
10.14 Info�� 87
10.15 Extras�� 87
10.15.1 Slow-Mode�� 87
10.15.2 Dosing monitoring�� 87
10.15.3 Diaphragm rupture detection (OPTION)�� 88
10.15.4 Level monitoring�� 89
10.15.5 Venting automatic (only with CS 409.2)�� 90
11. Maintenance�� 92
11.1 Working materials�� 93
11.2 Drive unit�� 94
11.2.1 Drive motor�� 94
11.2.2 Oil change�� 94
11.3 Dosing unit�� 95
11.3.1 Overview of the tightening torques�� 95
11.3.2 Changing the Diaphragm�� 96
12. Spare and wearing parts�� 100
12.1 Wearing parts�� 100
12.2 Spare parts�� 100
12.3 Spare and wearing parts�� 101
12.3.1 Diaphragm pump C 409.2- 0,8 e ...-2,4 e�� 101
12.3.2 Diaphragm pump C 409.2- 4,0 (e) ...-180 (e)�� 102
12.3.3 Diaphragm pump C 409.2-250 (e) ...-350 (e)�� 104
12.3.4 Diaphragm pump C 409.2- 4,0 (e) ...-180 (e)
with integrated overflow valve�� 106
12.3.5 Diaphragm pump C 409.2-250 (e) ...-350 (e)
12.3.6 Diaphragm pump CS 409.2- 0,8 e ...-2,4 e�� 110
12.3.7 Diaphragm pump CS 409.2- 4,0 (e) ...-25 (e)�� 112
12.3.8 Diaphragm pump CS 409.2- 4,0 (e) ...-25 (e)
13. Fault analysis and corrective action�� 116
13.1 Analysis of the plain text error messages�� 116
13.2 Analysis of other faults�� 118
14. Shut-down�� 120
15. Disposal�� 120
15.1 Dismantling and transport�� 120
15.2 Complete disposal�� 120
16. Clearance Certificate�� 121

C/CS 409.2
Q. Quickstart
“Quickstart” is used to start-up the pump quickly without having read the operating instructions in detail.
The Quickstart does not claim to be complete and does not relieve the user from
reading the complete instruc-tions!
INFO!
Q.1 Power connection

The sera diaphragm pump is delivered ready for installation. Standard delivery includes a 2m power cable with Euro
plug. The standard version C 409.2 is designed for an operating voltage range of 210 – 250 V, 50/60 Hz.
The self-venting version CS 409.2 has a limited operating voltage range. The
specifications on the type plate must absolutely be adhered to!
The CS 409.2 is available in three versions:

ATTENTION!
■■ 210 – 250 V, 50/60 Hz
■■ 100 – 120 V, 50 Hz
■■ 100 – 120 V, 60 Hz
The pump restarts in the selected operating mode after the power supply was
switched on or a power supply recovery following a mains failure!
ATTENTION!
Symbol:
Only operate the pump when it is connected to an earthed power supply!
ATTENTION!

C/CS 409.2
Q.2 Control elements
2
5
1 6
1 STOP/START key
2 LED operation indications
3 LCD-display
4 UP key
5 DOWN key
6 ENTER key
Q.3 LED operation indicators

Three light-emitting diodes (LED) indicate the status of the pump:
Green: Operation and stroke indicator

When switching on the pump, the green LED lights steadily. The operation indicator works in combina-
tion with a stroke indicator; during pump operation, the LED flashes in accordance with the current stroke
frequency.
Yellow: Warning indicator

The yellow LED indicates all occurring warning messages (cp. table "Overview LED Operation Indicator"
in chapter “LED Operation Indicator"). The warning is not only indicated by the LED but also as plain text
in the LCD display.
Red: Fault indicator

The red LED indicates all occurring faults (cp. table "Overview LED Operation Indicator" in chapter “LED
Operation Indicator"). The fault is not only indicated by the LED but also as plain text in the LCD display.

C/CS 409.2
Q.4STOP
Key operation
START
Operation of the pump is performed with 4 keys:
STOP
STOP/START key
START After connection to the power supply, the pump is switched ON/OFF using the STOP/START
STOP key.
START
ENTER
ENTER key
You can use the ENTER key to open and confirm value input fields and to select menu items.
ENTER
ENTER
UP- / DOWN key
Using the UP/DOWN key, you can scroll the different menu items / menu levels and select the
display of various operating messages.
During parameter adjustment, the UP key is used to increase the parameter value and the
DOWN key is used to decrease the parameter value.
Q.5 Factory settings

The factory setting of the pump electronics is specified in Chapter “Parameter table”.

C/CS 409.2
Q.6 Control inputs and outputs
Q.6.1 Control via contact signal
Figure: "Control of digital inputs via a potential-free contact signal and control of a relay via an output of the dosing pump”
RD + BU
-
PK
GY Collecting Fault (15V DC) +
YE
GN Extern Stop
BN
Contact signal
WH Pulse
Contact signal
Q.6.2 Control via analog signal
Figure: "Control of analog/digital inputs via an analog signal, potential-free contact signal and control of a relay via
an output of the dosing pump”
Control cabinet customer
0V (Ground) / -4...20mA
RD + BU
-
PK
GY Output 01 Collecting fault max. 50 mA +
YE
GN Extern Stop
BN Analog 01
+4 ... 20mA
WH

C/CS 409.2
STOP STOP
Q.7 Selecting the operating mode
START START
Proceed as follows to select the operating mode:
■■ Input the password PW01 (factory setting 9990) to release the programming levels.
ENTER ENTER
■■ Change the operating mode.
STOP
START
Operation Menu e.g. current stroke frequency (depending on chosen operation mode)
STOP
START
+ ENTER
STOP
START
PW01 STOP STOP
START START ENTER
Main Menu
Manual
ENTER
Pulse
>Operation
Operation Mode ENTER ENTER Analog
Mode<
Batch
Extern
PW02
PW01 Locking by password 01 (pre setting ex work: 9990, not activated)

PW02 Locking by password 02 (pre setting ex work: 9021)

C/CS 409.2
1. General
1.1 General user information

Before commissioning and during operation of the sera dosing pump the respective regulations valid at the place of
installation are to be observed.
The sera dosing pump is delivered ready for installation. Carefully read these instructions and especially the safety
instructions herein contained before installation and initial start-up of the pump.
1.2 Symbols and notes used in these operating instructions

Special notes in these operating instructions are marked with text and danger symbols.
Designation of the note Danger type Definition of the note
(Text and symbol) (in the operating instructions)

Danger of fatal injury
Damage to property
Risk of injury
Identifies an imminent danger

DANGER! X X X that results in fatal or severe injuries if not
avoided.
Designates a potentially dangerous situation

WARNING! X X X There might be danger to life or serious injury and
damage to property if it is not avoided.

CAUTION! X X There might be slight or minor injury or damage to
property if it is not avoided.

ATTENTION! X that could lead to damage to property if not
avoided.
Designates information which helps to make work

NOTE! easier and is useful for trouble-free operation.
1.3 Notes attached to the product

Symbols which are directly attached to the pump, e.g. arrows for direction of rotation or symbols for fluid connections
are to be observed and kept in legible condition.

C/CS 409.2
1.4 Quality instructions

Observance of these operating instructions and, in particular, the safety instructions, helps to
■■ avoid dangers to persons, machines and environment.

■■ increase reliability and service life of the product and the complete system.
■■ reduce repair cost and downtime.
The sera quality management and quality assurance system for pumps, systems, valves and fittings and compres-
sors is certified according to ISO 9001:2008.
The sera product meets the valid safety and accident prevention regulations.
Always keep these operating instructions within reach at the place of installation.
ATTENTION!
Pay attention to the safety data sheet of the medium! The owner must take cor-
responding accident prevention measures to protect operating personnel from
danger through the delivery media used!
WARNING!
2. Safety instructions
2.1 Personnel qualification and training

The personnel for operation, maintenance, inspection and installation must be suitably qualified for their tasks. The
owner must clearly define responsibility and supervision of the personnel.
If the personnel do not have the knowledge required, then personnel is to be trained and instructed correspondingly.
Such training can be provided by the manufacturer / supplier upon order of the owner. In addition, the owner has to
ensure that personnel have understood the operating instructions completely.
2.2 Dangers in case of inobservance of the safety instructions

Inobservance of these safety instructions can result in danger to persons, hazards to the environment and damage
to the product.
Inobservance of the safety instructions may lead to:
■■ Failure of important functions of the product/system.

■■ Inobservance of prescribed methods for maintenance and servicing.
■■ Danger to persons through electrical, mechanical and chemical influences.
■■ Hazards to the environment through leaking dangerous media.
2.3 Safety conscious working

The safety instructions specified in this operating manual, the national regulations for accident prevention, the safety
regulations for the pumped medium valid at the place of installation as well as internal working-, operating-, and safety
instructions of the owner are to be observed.

C/CS 409.2
2.4 Safety instructions for owner / operator

Leaking hazardous delivery media and operating supplies are to be disposed off in such a way that any danger to
persons and the environment is excluded. The legal regulations are to be observed.
Danger caused by electrical energy is to be avoided.
2.5 Safety instructions for maintenance, servicing and installation work

The owner must ensure that any maintenance-, servicing- and installation work is only entrusted to authorized and
suitably qualified personnel who have carefully read and understood the operating instructions.
Only those spare parts and operating supplies are to be used which meet the requirements of the specified opera-
ting conditions.
Threaded joints and connections may only be disconnected when the system is not under pressure.
2.6 Arbitrary modification and production of spare parts

Modifications of or changements to the pump are only permitted after previous agreement of the manufacturer. Origi-
nal spare parts and accessories which were approved by the manufacturer are essential for safety reasons.
If the pumps (e.g. drive motor) are modified without au-thorization of the manufac-
turer or spare parts are used which are not approved, any warranty claim becomes
null and void.
CAUTION!
2.7 Improper operations

Operating safety of the supplied product is only guaranteed if the product is used as intended, according to the
descriptions in Chapter 2.8 of these operating instructions.
2.8 Intended use

The sera product is only to be deployed according to the intended purpose stated in the product description and the
acceptance test certificate.
If the product is to be used for other applications, then the suitability of the product for the new operating conditions
must be discussed with sera beforehand!
Criteria for operation in accordance with the intended use:
■■ Observe characteristics of the medium (please see safety- and product data sheet of the delivery
medium – the safety data sheet is to be provided by the supplier / owner of the medium).
■■ Resistance of the materials which come into contact with the medium.
■■ Operating conditions at the place of installation.
■■ Pressure and temperature of the medium.
■■ Voltage supply.

C/CS 409.2
2.9 Operating conditions

■■ Ambient temperature: 0°C to 40°C
■■ Climate: relative air humidity < 90%
■■ Installation altitude: max 1000m above sea level
■■ Pump design data for dosing and its temperature can be found in the order confirmation.
2.10 Personal protection for maintenance and service

The provisions of the German Ordinance on Hazardous Substances (GefStoffV) (§14 Safety Data Shee) and relevant
national safety regulations for the pumped medium must strictly be adhered to.
In case of accidents check whether the following substances are emitted:
■■ Leaking fluids.
■■ Leaking vapours.
■■ Noise emissions (sound level).
Emissions are to be monitored by corresponding controly systems of the total installation.
Wear protective clothing, gloves, breathing mask and a face protecting mask.
ATTENTION!
Personal protective equipment must be provided by the owner!
NOTE!
NOTE!
2.11 Utilities/Lubricants
If not agreed otherwise in the contract conditions, the sera dosing pump will always be supplied with the necessary
utilities. (For type and quantitiy of utilities/lubricants, see Chapter 11.1 „Working materials“).

C/CS 409.2
2.11 Foreseeable misuse

The following misuse is assigned to the life cycles of the machine.
Misuse can result in danger to the operating personnel!
DANGER!
2.11.1 Transport
■■ Tipping behavior during transport, loading and unloading ignored.
■■ Weight for lifting underestimated.
2.11.2 Assembly and installation

■■ Power supply not fuse protected (no fuse/fuse too large, power supply not conforming to standards).
■■ No or improper fastening material of the pump.
■■ Improper connection of the pressure pipes, wrong material i.e. PTFE tape and unsuitable connection pieces.
■■ Liquid pipes confused.
■■ Threads overturned/damaged.
■■ Pipes bent during connection in order to compensate for alignment errors.
■■ Supply voltage connected without earthed conductor.
■■ Socket for safe disconnection of the power supply difficult to reach.
■■ Wrong connecting cables for supply voltage (cross-section too small, wrong insulation).
■■ Parts damaged (e.g. vent valve, flow meter broken off).
■■ Wrongly dimensioned pressure and suction pipe.
■■ Incorrect dimensioned and improperly fastened pump panel (panel broken off).
■■ The pumped medium is conveyed into the environment in the case of pumps with automatic or manual vent
valve if the return pipe was improperly fitted or not fitted at all. ► Danger for the operator.
■■ Mains plug cut off (direct connection), safe disconnection impossible. Safe disconnection e.g. by
2-pin main switch.
■■ Short circuit of the internal power supply (15V DC) at the control cable during installation.
■■ Admissible current load of the digital outputs exceeded
■■ No sera sensors for flow or filling level ► damage to the electronics.
■■ No diode for external control power supply connection ► electronics overloaded/destroyed.
■■ Electronics opened in order to connect the mains cable directly to the power supply ► electric shock or
damage to the electronics.
■■ Connection of wrong supply voltage or mains frequency ► electronics or vent valve destroyed.
2.11.3 Start-up
■■ Cover on vent openings (e.g. motor).
■■ Suction or pressure pipes closed (i.e. foreign matters, particle size, stop valves).
■■ Start-up with damaged system.
■■ Integrated overflow valve misadjusted (no protection function).
■■ Operation without connected return pipe of the integrated overflow valve.
■■ No free return flow of the overflow valve.
■■ Operation without connected return pipe of the vent valve.
■■ Sensor cable damaged (electronics <--> stroke mechanism), wrong or no recognition of the stroke
length ► wrong dosing volume and resulting process error.
■■ Wrong parameterization of the pump ► inadvertent start.
■■ Distance between dosing pump and other dosing pumps or electrical consumers insufficient ► fault by elec-
tromagnetic radiation..

C/CS 409.2
■■ Control cables too long >> 30m ► malfunctions due to EMC.
■■ Control cable and power cable laid in parallel ► malfunctions due to EMC.
2.11.4 Operation
■■ Fault message ignored ► faulty dosing / process error.
■■ Pipes hit, pulsation damper not used ► damage to the pipes, medium is leaking.
■■ Pumped medium contains particles or is contaminated.
■■ External fuse bridged ► no cut off in case of an error.
■■ Ground wire removed ► no cut off by fuse in case of an error, supply voltage directly at the housing.
■■ Insufficient lighting of the working place.
■■ Suction height too high, pump capacity too low ► process error.
■■ Arbitrary modification of the pump (valves, internal fuse, …).
■■ Integrated overflow valve misadjusted.
■■ No free return flow of the integrated overflow valve.
■■ No supervision of leakages ► MBE opening.
■■ Diaphragm rupture is not indicated when the MBE plug was disconnected. Medium can escape into the envi-
ronment through the vent hole “Danger to the operator and the environment”.
2.11.5 Maintenance / Repair

■■ Works carried out which are not described in the operating instructions (works on the stroke mechanism and
the assembly pump, electronics opened).
■■ Prescribed maintenance schedules ignored.
■■ Use of wrong spare parts/oils (e.g. no sera original spare parts, wrong viscosity).
■■ Improper mounting of spare and wearing parts (e.g. wrong tightening torque for pump body).
■■ Oil level not checked.
■■ Use of cables with damaged insulation.
■■ No shut down / no protection against a restart before maintenance work.
■■ Pumped medium or utilities during an oil change insufficiently removed.
■■ Restart without sufficient fastening.
■■ Valves confused.
■■ Sensor pipes confused.
■■ Pipes not connected (e.g. suction- and pressure pipes, gas pipes).
■■ Gaskets damaged, medium is leaking.
■■ Gaskets not fitted, medium is leaking.
■■ Wearing of unsuitable protective clothing / no protective clothing at all.
■■ Operation of an uncleaned system.
■■ Pumped medium contaminated with oil.
■■ Poorly ventilated room.
■■ If the screw-in depth of the setscrew for the integrated overflow valve is not noted, this may lead to dan-
gerous consequences, i.e. rupture of the pressure pipe or leaking medium. …).
2.11.6 Cleaning
■■ Wrong rinsing medium (material changed, reaction with the medium).
■■ Wrong cleaning agent (material changed, reaction with the medium).
■■ Cleaning agent remains in the system (material changed, reaction with the medium).
■■ Protective clothing insufficient or missing.
■■ Use of unsuitable cleaning utensils (material changed, mechanical damage by high pressure cleaner).
■■ Untrained personnel.
■■ Vent openings clogged.
■■ Parts torn off.
■■ Sensors damaged.

C/CS 409.2
■■ Non-observance of the safety data sheet.
■■ Control elements actuated.
2.12.7 Shut-down
■■ Pumped medium not completely removed.
■■ Disassembly of pipes with the pump running/with residual pressure.
■■ Disconnection of the electrical connections in a wrong sequence (ground wire first).
■■ Disconnection from the power supply not ensured ► danger through electricity.
2.12.8 Disassembly
■■ Residues of the pumped medium and utilities in the system.
■■ Use of wrong disassembly tools.
■■ Wrong or no protective clothing at all.
2.12.9 Disposal
■■ Improper disposal of the pumped medium, utilities and materials.
■■ No marking of hazardous media.
■■ Wrong disposal of the elctronics.

C/CS 409.2
3. Transport and storage
3.1 General
sera products are checked for perfect condition and function previous to shipment.
Check for transport damage immediately after arrival of goods. If damage is found, this is to be reported immediately
to the responsible carrier and the manufacturer.
The packaging material must be disposed of appropriately!
NOTE!
3.2 Storage
An undamaged packaging protects the unit during storage and should only be opened when the product is installed.
Proper storage increases the service life of the product and includes prevention of negative influences such as heat,
moisture, dust, chemicals etc.
The following storage specifications are to be obsered:
■■ Storage place: cool, dry, dustfree and slightly ventilated

■■ Storage temperature between +2°C and +40°C
■■ Relative air humidity not more than 50 %.
■■ The maximum storage time for the standard system is 12 months.
If these values are exceeded, metal products should be sealed in foil and protected from condensation water with a
suitable desiccant.
Do not store solvents, fuels, lubricants, chemicals, acids, disinfectants and similar in the storage room.

C/CS 409.2
4. Product description
4.1 Types
4.1.1 Type key
Type of drive (combinations possible)

C controllable
S self ventilating
M not adjustable
R generally adjustable
F Motor suitable for frequency converter operation
i Frequency converter, mounted on the motor
P Pole-changing motor
K Stroke mechanism with side drive shaft and connected to the drive via a clutch
Z twin design
X Stroke mechanism with two opposite pump heads, combined suction and pressure side
Y Stroke mechanism with two opposite pump heads
Series
204 (solenoid driven pumps)
409 (motor driven pumps)
Revision index
max. Nominal capacity (litre/hour (each pump head))
Displacer (type of construction)

(without) Double diaphragm
e Single diap hragm
ML Multy-layer diaphragm
KM Piston Diaphragm
K Piston
1 2 3 4 5
C 409 . 2 - 50 e (example)

C/CS 409.2
4.1.2 Type plate

Each sera dosing pump is factory provided with a type plate.
The following information can be found on this type plate.
1
Type
No. Q l/h
2 N 7
P1 min/max bar n 1/min
N
3 P2 max bar Hydrfl cm3 6
4 5
No. Designation
1 Pump type
2 Serial number of the pump
Minimum/maximum permissible pressure in the pump inlet

Minimum/maximum permissible pressure in the inlet cross section which the pump can be used for.
3 Please consider that pressure depends on rotation speed, delivery rate, temperature and static pressure
at the inlet.
Maximum permissible pressure in the pump outlet

Maximum permissible pressure in the outlet cross section which the pump can be used for. Please consi-
4 der that pressure depends on rotation speed, delivery rate, temperature and static pressure at the outlet.
Buffer fluid
5 Quantity of buffer fluid in the diaphragm ring (in the case of double diaphragm pumps).
6 Nominal stroke frequency
Nominal delivery rate

7 Delivery rate which the pump was ordered for, based on the nominal rotation speed nN, the nominal deli-
very height p2max. and the delivery medium stated in the supply contract.
4.2 Materials
The materials used are stated in the order confirmation and the product description.
4.3 Viscosity, pumped medium

The diaphragm pump is suitable for fluids with viscosities < 100 mPas.
4.4 Dosing range

The delivery rate of the diaphragm pump can be set manually via the stroke length adjustment (0…100%).
The linear dosing range is between 20% and 100%.
4.5 Noise measurement

According to DIN 45635 the sound pressure level measured of the diaphragm pumps is between 50 and 65 dB (A).

C/CS 409.2
4.6 Components of the diaphragm pump
4.6.1 C409.2
3
2
1
14
13
5
12
11
8 7
10
No. Designation Remark

1 Electronics
2 Driving motor
3 Manual stroke length adjustment
4 Manual stroke length adjustment with position indicator option
5 Stroke length adjustment with actuator option
6 Stroke mechanism
7 Suction valve
8 Assembly pump (double diaphragm design)
9 Diaphragm rupture electrode MBE-03 (for double diaphragm pumps) option
10 Diaphragm rupture electrode MBE-02 (for single diaphragm pumps) option
11 Assembly pump (single diaphragm design)
12 Pump body
13 Pump body with integrated overflow valve
14 Pressure valve

C/CS 409.2
4.6.2 CS409.2
3
2
1
15 4
14
13
5
12
11
10
9
8
No. Designation Remark

1 Electronics
2 Driving motor
3 Manual stroke length adjustment
4 Manual stroke length adjustment with position indicator option
5 Stroke length adjustment with actuator option
6 Stroke mechanism
7 Suction valve
8 Assembly pump (double diaphragm design)
9 Diaphragm rupture electrode MBE-03 (for double diaphragm pumps) option
10 Diaphragm rupture electrode MBE-02 (for single diaphragm pumps) option
11 Assembly pump (single diaphragm design)
12 Pump body
13 Pump body with integrated overflow valve
14 Pressure valve
15 Vent valve

C/CS 409.2
4.7 Functional description
4.7.1 General
sera dosing pumps are run-dry safe oscillating displacement pumps that are characterised by high tightness of the
dosing head. The fluid is conveyed by a deformable diaphragm.
Controllable diaphragm pumps consist of the following (main) components:
■■ Stroke mechanism
■■ Drive motor
■■ Electronics
■■ Stroke length adjustment
■■ Assembly pump
■■ Pump body
■■ Suction and pressure valve
■■ Automatic ventilation device (CS-design)
4.7.2 Stroke length adjustment

Piston diaphragm pumps of this type series use a rotary cam
drive to transmit the rotation of the drive motor to the displace-
ment body.
In case of the rotary cam drive, the eccentric (2) provides the
pressure stroke while the suction stroke is performed by a pres- 1
sure spring (return spring) (3).
The effective stroke length can be changed by means of an
2
adjustable scale knob (1) which prevents the connecting rod
from following the rotary cam up to the rear dead centre during
suction stroke (see stroke length adjustment). 3
4.7.3 Drive motor

A sera diaphragm pump of series C/CS 409.2 is driven by a threephase-motor controlled by the electronics.
4.7.3.1 Motor protection

A protective motor switch is not necessary due to the fact that a thermic overload protection is integrated in the
pump for the protection of the motor.

C/CS 409.2
4.7.4 Stroke length adjustment

The delivery rate of the pump is set by changing the stroke length. The stroke length is infinitely variable between
0% and 100%.
A linear dosing behaviour is achieved with stroke length adjustments between 20% and 100%.
4.7.4.1 Manual stroke length adjustment (standard)

The effective stroke length of the connecting rod is changed
by turning the scale knob.
The stroke length should be adjusted during operation of
the pump.
The set stroke length can be read off a scale, e.g. 75% (see
Fig.).
With the 20-steps adjustment on the scale knob, the stroke
length can be set individually with a tolerance of 0.5%.
- l/h + l/h
Protection for stroke length adjustment (option)
A protecting cap can be provided for the protection of the

stroke length adjustment against unintentional adjustment.

C/CS 409.2
4.7.4.2 Manual stroke length adjustment by a dial scale with indication of

percent (option)
The stroke length is adjusted by turning the hand wheel.
The stroke length shuold be adjusted during operation of
the pump.
The set stroke length can be read off the percent scale (the
example shows a set stroke length of 65%).
In delivery state, the stroke length adjustment is factory set
to 50%.
- l/h + l/h
The dial scale with indication of percent may become misadjusted during
transport.
If the indicator does not match the 50% setting, then the percent scale must
be re-adjusted during operation (!) of the pump!
ATTENTION!
Adjusting the percent scale:
■■ Switch on the piston diaphragm pump.

1
■■ Loosen setscrew (1).
■■ Remove percent scale (2) from the hand wheel (3).
■■ Manually turn the percent scale to 0% setting.
■■ Use the hand wheel to set the stroke length to 0%.
Turn hand wheel clockwise until there is no further stro- 2
ke movement (connecting rod does no longer hit the
4
adjusting spindle (4)).
■■ Insert percent scale again.
■■ Use the setscrew to secure the percent scale to the 3
hand wheel.
■■ Adjust desired stroke length.

C/CS 409.2
4.7.4.3 Automatic stroke length adjustment by means

of an electrical actuator
The electrical actuator is directly mounted to the stroke me-
chanism (1) of the dosing pump. A clutch transmits the rota-
ry motion of the actuator drive shaft to the adjusting spindle.
The axial displacement is compensated in the clutch (2).
In case of dosing pumps with electrical actuator, a manual
adjustment of the stroke length on the pump is no longer
possible.
(Exception: actuator with hand wheel)
The actuator is equipped with two integrated limit switches
as well as a position potentiometer for position feedback as
standard.
Both limit switches are factory set so that the drive will
2
switch off at a stroke length of 0% and 100%, even if a con-
1
trol voltage is applied.
This guarantees that adjustments can only be made within
the permissible range. The position potentiometer is driven
by a safety clutch which prevents damage caused by incor-
rectly adjusted limit switches.
Activation is performed by appropriate control units
(see sera - accessories)
The set stroke length can be read off on the pump (percent scale)
Information on the electrical connection is given inside the cover of the actuator.
The adjustment is only possible when the pump is running.
ATTENTION!
4.7.4.4 Automatic stroke length adjustment by means

of an electrical actuator with integrated positioner (PMR3)
same as Chapter 4.7.4.3, additionally:
■■ PMR3 positioner
This PMR3 positioner which is integrated in the actuator enables an actuator setting from 0…100% that is
proportional to the connected input signal.
As an option, the actuator can also be provided with a collective interference signal.
Information on the electrical connection is given inside the cover of the actuator.

C/CS 409.2
4.7.5 Assembly pump

There are two different pump types:
A
■■ Single diaphragm pump (A)
■■ Double diaphragm pump (B)
2
Single diaphragm pump (A) 1
3
The drive diaphragm (2) connected to the drive via the con-
necting rod (1) transmits the stroke movement directly to the
pumped medium (3).
Double diaphragm pump (B)

B 4
The stroke movement of the drive diaphragm (2) is transmitted
hydromechanically to the intermediate diaphragm (4) which is
in contact with the medium.
The intermediate diaphragm protects the drive diaphragm from 2
chemical affects of the pumped medium (3).
3
1
5
A proper function can only be guaranteed when there are no
gas- or air bubbles in the hydraulic chamber and the correct
volume of buffer fluid has been filled in.
4.7.6 Pump body

Depending on the applied backpressure, movements of the plastic pump body in elastic materials are possible.
This does not affect the pumps’s service life or operational reliability.
4.7.7 Pump body with integrated overflow valve

The integrated diaphragm overflow valve protects the pump
from unacceptable overpressure at closed pressure line. Pipes
and fittings, however, are not protected and have to be pro-
tected separately, if necessary. It can be used for liquid media
without solid matters according to the manufacturer specifica-
tions.
Pump bodies with integrated overflow valve are equipped with

an additional relief channel (1) through which the pumped me- 4
2
dium is drained in case of an unacceptable overpressure.
The relief channel is closed by the mechanically prestressed
diaphragm (2) of the overflow valve.
The mechanical prestress which is executed by a pressure 1

spring (3) can be adjusted with a set screw (4). If the pressure 3
of the pumped medium on the diaphragm exceeds the set pres-
sure, the diaphragm is lifted and the pumped medium flows into
the relief channel.
When the pressure in the pump body falls below the pressure
set the diaphragm closes the inlet channel again.

C/CS 409.2
The integrated overflow valve is always set to the maximum pump pressure (P2
max.) if no other value is specified.
CAUTION!
4.7.8 Suction / Pressure valve

The pump valves are ball valves that only work properly in a
vertical position. The condition of the valves has a deciding ef-
fect on the operating capability of the pump.
Valves must be exchanged as complete units. 1
When replacing the valves it is important to check the flow di-

rection (1).
Pressure valve above; Suction

valve below!
ATTENTION!
4.7.9 Electronics (operating panel)

The electronics permit proportional volumetric dosing via ana- 1 2
logue signals 0/4 ... 20 mA or contact signals with the option of
dividing or duplicating the pulse.
An integrated LCD display (2) and three LED’s (1) for warning
and fault display indicate the current status of the dosing pump.
A connection for flow monitoring or flow measurement as well
as an empty signal with pre-alarm and dry operation alarm are
installed as standard (see chapter „Electric supply“).

C/CS 409.2
4.7.10 Diaphragm rupture monitoring device (option)

sera - diaphragm pumps of the 409.2 series can be equipped with a conductive diaphragm rupture monitoring
device as option.
The sensitivity of the diaphragm rupture electrode can be adapted to the con-
ductivity of the medium via the electronics (see Chapter „Diaphragm rupture
detection“ (Operation)).
Preset ex works to 50% approx. 10 µS/cm.
NOTE!
One must distinguish between the single and the double diaphragm pump.
The diaphragm rupture electrode type MBE-02 is used for single diaphragm pumps, type MBE-03 or MBE-04 for
double diaphragm pumps.
MBE-02
The diaphragm rupture electrode type MBE-02 is not mounted

by sera due to transport. We put the MBE-02 electrode onto the
cable (3) and fix it to the pump in a separate bag.
Mounting MBE-02
■■ Put the diaphragm rupture electrode type

MBE-02 (2) is in the base ring (1) of the dosing pump
from below.
1
3
2
MBE-03/04
The diaphragm rupture electrode type MBE-03/04 is

mounted in the side of the diaphragm ring of the dosing
pump. (please see Fig. in Chap. „Components of the dia-
phragm pump“).
4.7.11 Manual vent valve (only FRP-execution C 409.2-0,8e - …-2,4e)

The vent valve is used to release the manual pressure in the pump body (4) during commissioning. Open vent
valve when pump primes first time.
When vent valve is opened gas including medium escapes into the feedback line. The vent valve must be closed
again as soon as only medium without gas constituent escapes. The pump now feeds the medium into the pres-
sure line.

C/CS 409.2
Open again for another ventilation. The vent valve consists of a
vent screw (1) with integrated hose nozzle (2), which must be
fitted with a hose (3) (inside diameter 6 mm) as feedback line.
The leaking medium incl. the gas admixtures must be disposed
off properly.
The vent screw is inserted during normal operation. 1
Open vent screw with great caution and perform max. 1 turn. Take care that the
tightness of the thread is still guaranteed.
ATTENTION!
The vent screw must always be closed during the driving process.
ATTENTION!
4.7.12 Automatic ventilation device (CS-design)

The self ventilating controllable diaphragm pumps are equip-
ped with a vent valve which is installed on the pump pressure
nozzle and which cannot be retrofitted.
The pump vents the dosing head of the pump and the suction
line, either externally or manually controlled or automatically at
a predefined interval. 1
The vent valve consists of a combination of a check valve (1),
2
which should prevent a back-flow of the medium, and a sole-
noid valve (2). When the controlled solenoid valve opens the
3
spring-loaded rotor with attached seal is lifted from the valve
seat and pressure is relieved from the space between the pump
valve and the integrated check valve.
Thus pump and the pipes on the suction side can be vented
without pressure.
Please note that the required stroke volume is covered by the

usable stroke length range.
Always install the pump above the suction tank and lay the return pipe (3) with
descending gradient to the suction tank!
CAUTION!

C/CS 409.2
5. Technical data
5.1 Performance data

Type
sible pressure in the
length range with

Maximum permis-
mum permissible
rate adjustable
stroke frequency
Nominal delivery
Minimum / maxi-
suction height (1)
self-ventilation
by stroke length
adjustment and
Usable stroke
Nominal stroke
pressure in the
Outlet nominal
nominal width
stroke length
pump outlet
adjustment
pump inlet
frequency
Maximum
Maximum
Weight (5)
width
Inlet
(2)
QN QN p2 p1
WC DN DN min-1 h100
l/h ml/stroke max. min./max.
50/60Hz bar bar m % mm mm 50/60 Hz mm kg
2 80 - 100
CS 409.2 – 0,8 e 0 - 0,8 0 - 0,13 10 -0,2/0 4 5 100 1,6 11,1
1 40 - 100
CS 409.2 – 1,6 e 0 - 1,6 0 - 0,27 10 -0,3/0 3 50 - 100 4 5 100 1,6 11,1
CS 409.2 – 2,4 e 0 - 2,4 0 - 0,27 10 -0,3/0 3 50 - 100 5 5 150 1,6 11,1
2 40 - 100 (4)
CS 409.2 – 4,0 (e) 0 - 4,0 0 - 0,67 10 -0,3/0 5 5 100 4 11,1

3 60 - 100
CS 409.2 – 7,0 (e) 0 - 7,0 0 - 0,78 10 -0,3/0 3 45 - 100 (4) 5 5 150 4 11,1
CS 409.2 – 12 (e) 0 - 12 0 - 3,0 10 -0,3/0 3 30 - 100 (3) 5 10 67 6 11,1
CS 409.2 – 18 (e) 0 - 18 0 - 3,0 10 -0,3/0 3 30 - 100 (3)
5 10 100 6 11,1
CS 409.2 – 25 (e) 0 - 25 0 - 2,8 10 -0,3/0 3 30 - 100 (3) 5 10 150 6 11,1
Type
pressure in the pump
stroke length adjust-
ment and stroke fre-
sible pressure in the

quency adjustment
Nominal delivery (2)
Maximum permis-
rate adjustable by
mum permissible
Minimum / maxi-
suction height (1)
Nominal stroke
nominal width
stroke length
pump outlet
Inlet / outlet
frequency
Weightt (5)
Maximum
Maximum
inlet
QN QN p2 p1
WC DN min-1 h100
l/h ml/stroke max. min./max.
50/60Hz bar bar m mm 50/60 Hz mm kg
C 409.2 – 0,8 e 0 - 0,8 0 - 0,13 10 -0,2/0 2 5 100 1,6 10,7
C 409.2 – 1,6 e 0 - 1,6 0 - 0,27 10 -0,3/0 3 5 100 1,6 10,7
C 409.2 – 2,4 e 0 - 2,4 0 - 0,27 10 -0,3/0 3 5 150 1,6 10,7
C 409.2 – 4,0 (e) 0 - 4,0 0 - 0,67 10 -0,3/0 3 5 100 4 10,6
C 409.2 – 7,0 (e) 0 - 7,0 0 - 0,78 10 -0,3/0 3 5 150 4 10,6
C 409.2 – 12 (e) 0 - 12 0 - 3,0 10 -0,3/0 3 10 67 6 10,7
C 409.2 – 18 (e) 0 - 18 0 - 3,0 10 -0,3/0 3 10 100 6 10,7
C 409.2 – 25 (e) 0 - 25 0 - 2,8 10 -0,3/0 3 10 150 6 10,7
C 409.2 – 50 (e) 0 - 50 0 - 8,3 10 -0,3/0 3 10 100 8 10,5
C 409.2 – 75 (e) 0 - 75 0 - 8,3 10 -0,3/0 3 15 150 8 12,6
C 409.2 – 90 (e) 0 - 90 0 - 15,0 8 -0,3/0 3 15 100 10 14,1
C 409.2 – 115 (e) 0 - 115 0 - 19,2 4 -0,3/0 3 15 100 10 14,1
C 409.2 – 140 (e) 0 - 140 0 - 15,6 8 -0,3/0 3 15 150 10 14,1
C 409.2 – 180 (e) 0 - 180 0 - 20,0 4 -0,3/0 3 15 150 10 14,1
C 409.2 – 250 (e) 0 - 250 0 - 41,7 3 -0,3/0 3 15 100 10 16,6
C 409.2 – 350 (e) 0 - 350 0 - 38,9 3 -0,3/0 3 15 150 10 16,6
(1)
Achievable height with media similar to water and filled suction line
(2)
Linear dosing range at a stroke length between 20% and 100% and at a stroke frequency between 5 and 100%
(3)
Controllable diaphragm pump with integrated overflow valve: Usable stroke length range with self-ventilation 40-100%
(4)
Controllable diaphragm pump with integrated overflow valve: Usable stroke length range with self-ventilation 50-100%
(5)
Standard design
The nominal data refer to water, 20°C and nominal pressure. With lower counterpressure it can come to be soaked off achievements.

C/CS 409.2
5.2 Motor data
Protection category
Type 230V, 50/60 Hz 115V, 50 Hz 115V, 60 Hz
Thermal class
Frequency
Nominal
Nominal
Nominal
Nominal
Nominal
Nominal
voltage
voltage
voltage
current
current
current
Output
Size
BG kW Hz V A V A V A IP
CS 409.2 – ...(e) 63 0,18 50 / 60 210 - 250 3,0 100 - 120 6,0 100 - 120 6,0 55 F
Protection category
Type 230V, 50/60 Hz 115V, 50/60 Hz
Thermal class
Frequency
Nominal
Nominal
Nominal
Nominal
voltage
voltage
current
current
Output
Size
BG kW Hz V A V A IP
C 409.2 – 0,8 e 63 0,18
C 409.2 – 1,6 e 63 0,18
C 409.2 – 2,4 e 63 0,18
C 409.2 – 4,0 (e) 63 0,18
C 409.2 – 7,0 (e) 63 0,18
C 409.2 – 12 (e) 63 0,18
C 409.2 – 18 (e) 63 0,18
C 409.2 – 25 (e) 63 0,18
50 / 60 210 - 250 3,0 100 - 125 6,0 55 F
C 409.2 – 50 (e) 63 0,18
C 409.2 – 75 (e) 71 0,37
C 409.2 – 90 (e) 71 0,37
C 409.2 – 115 (e) 71 0,37
C 409.2 – 140 (e) 71 0,37
C 409.2 – 180 (e) 71 0,37
C 409.2 – 250 (e) 71 0,37
C 409.2 – 350 (e) 71 0,37
5.3 Additional data for electronics
Typ Recommended fuse

Analogue input resistance
Min. contact signal time
betrween pusles
Inlet voltage /
Min. distance
Digital output
Control input
230V AC 115V AC
PNP,
internal supply max. 15V
C6A C10A
C/CS 409.2 – ...(e) 5…30 V DC 55 ms 100 Ω DC, 50 mA
Circuit breaker Circuit breaker
external supply max. 30V
DC, 350 mA

C/CS 409.2
5.4 Dimensions
5.4.1 C 409.2
b
K2
a
21
1 M8 / Ø 6,5
10
~ 190
80
75
39
194 (BG63) 147,5 (BG63) 47,5
215 (BG71) 154,5 (BG71) 80
98
2
min. 200
~ 245
~ 160
J3 / J4
I
J2
~ 110
J1
~ 305
32
II
148
X
A
C
C
B
E
G
I
H
Ø 6,5
K1 F
D S
1 Mounting holes
2 for removing the actuar cover
3 Manual vent valve (...409.2-0,8e - 2,4e, FRP-design)
Drive with electronics can be rotated throughout 90° each and can be put to the positions I and II.
4
(release the motor fastening screws, put the motor carefully to the desired position and fasten with screws again)

C/CS 409.2
All dimensions in mm! Single diaphragm pump
C 409.2-0,8e
C 409.2-1,6e
C 409.2-2,4e
C 409.2-4,0e
C 409.2-7,0e
C 409.2-12e
Single valves PVC --- --- --- 52 52 52
Double valves ..-FRP
PK (PP-FRP / PVDF-FRP) 80 80 80 56 56 56
S PK (PP / PVDF) --- --- --- 57 57 60
Double valves
1.4571/1.4581 --- --- --- 57 57 61
Chamber valves
PVC, PP, PVDF, 1.4571 70 70 70 --- --- ---
Single valves PVC --- --- --- 65 65 65

PK (PP-FRP / PVDF-FRP) 80 80 80 64 64 64
D PK (PP / PVDF) --- --- --- 57 57 60
Double valves
1.4571/1.4581 --- --- --- 57 57 61
Chamber valves
PVC, PP, PVDF, 1.4571 70 70 70 --- --- ---
Connection thread
G Suction/pressure valve G¾ G¾ G¾ G¾ G¾ G¾
A Assembly pump 16 16 16 17 17 14
B Centre of valve thread 17 17 17 15 15 16

Pump body (PB)
PB (without front plate) 43 43 43 36 36 36
PB (with front plate) 45 45 45 38 38 38

C
PB (FRP-design) --- --- --- 33 33 35
PB (FRP-design)
with manual vent valve 75 75 75 --- --- ---
Pump body with integrated
E over-flow valve --- --- --- 97 97 97
PB with integrated overflow
Overflow valve socket

(PVC, PP, PVDF) max. --- --- --- 47 47 47
F
(1.4571) max. --- --- --- 52 52 52
valve
Connection thread socket

H over-flow valve --- --- --- G¾ G¾ G¾
Distance: centre of valve thread
I – centre of overflow valve socket --- --- --- 0 0 0
b Angle, socket overflow valve --- --- --- 90° 90° 90°
Manual stroke length adjustment
J1 (SLA) (max.) 70 70 70 70 70 70
Manual SLA with position
J2 indica-tor 110 110 110 110 110 110
SLA
J3 Electrical actuator 240 240 240 240 240 240
J4 Electrical actuator with PMR3 320 320 320 320 320 320
MBE
Diaphragm rupture signalling

K1 MBE-02 67 67 67 67 67 67
Stroke a. o. Dimensions for fastening of
see dimensional drawing
mechanism the pump

C/CS 409.2

1)
Connection thread G1 for single valves PVC
C 409.2-140e
C 409.2-180e
C 409.2-250e
C 409.2-350e
C 409.2-115e
C 409.2-18e
C 409.2-25e
C 409.2-50e
C 409.2-75e
C 409.2-90e
Single valves PVC 52 52 70 70 78 78 78 78 --- 119 --- 119
Single valves ..-FRP
PK (PP-FRP / PVDF-FRP) --- --- 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) --- --- 67 67 75 75 75 75 122 --- 122 ---
Single valves
S 1.4571/1.4581 --- --- --- --- --- --- --- --- 122 --- 122 ---
PK (PP-FRP / PVDF-FRP) 56 56 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) 60 60 67 67 75 75 75 75 152 --- 152 ---
Double valves
1.4571/1.4581 61 61 68 68 76 76 76 76 152 --- 152 ---

PK (PP-FRP / PVDF-FRP) --- --- 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) --- --- 67 67 75 75 75 75 122 --- 122 ---
Single valves
D 1.4571/1.4581 --- --- --- --- --- --- --- --- 122 --- 122 ---
PK (PP-FRP / PVDF-FRP) 64 64 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) 60 60 67 67 75 75 75 75 152 --- 152 ---
Double valves
1.4571/1.4581 61 61 68 68 76 76 76 76 152 --- 152 ---
Connection thread
G Suction/pressure valve G¾ G¾ G¾ G¾ G¾ G¾ G¾ G¾ G1¼ G1 G1¼ G1
A Assembly pump 14 14 15 15 19 19 19 19 32 32
B Centre of valve thread 16 16 15 15 15 15 15 15 30 30

Pump body (PB)
PB (without front plate) 36 36 38 38 37 37 37 37 74 74
C PB (with front plate) 38 38 40 40 39 39 39 39 77 77
PB (FRP-design) 35 35 33 33 33 33 33 33 --- ---

Pump body with integrated over-
E flow valve 97 97 102 102 109 109 109 109 158 158

(PVC, PP, PVDF) max. 47 47 57 57 73 73 73 73 102 102
F
(1.4571) max. 52 52 62 62 77 77 77 77 110 110
valve

H over-flow valve G¾ G¾ G¾ G¾ G1 G1 G1 G1 G1¼ 1)
G1¼ 1)
I – centre of overflow valve socket 0 0 0 0 5 5 5 5 0 0
b Angle, socket overflow valve 90° 90° 90° 90° 90° 90° 90° 90° 45° 45°
J1 (SLA) (max.) 70 70 70 70 70 70 70 70 70 70
J2 indica-tor 110 110 110 110 110 110 110 110 110 110
SLA
J3 Electrical actuator 240 240 240 240 240 240 240 240 240 240
J4 Electrical actuator with PMR3 320 320 320 320 320 320 320 320 320 320
MBE

K1 MBE-02 67 67 67 67 67 67 67 67 102 102
mechanism the pump

C/CS 409.2
All dimensions in mm! Double diaphragm pump
C 409.2-4,0
C 409.2-7,0
C 409.2-12
Single valves PVC 52 52 52
PK (PP-FRP / PVDF-FRP) 56 56 56
S
PK (PP / PVDF) 57 57 60
Double valves
1.4571/1.4581 57 57 61
Single valves PVC 65 65 65

PK (PP-FRP / PVDF-FRP) 64 64 64
D
PK (PP / PVDF) 57 57 60
Double valves
1.4571/1.4581 57 57 61
Connection thread
G Suction/pressure valve G¾ G¾ G¾
A Assembly pump 29 29 28
B Centre of valve thread 15 15 16

Pump body (PB)
PB (without front plate) 36 36 36
C PB (with front plate) 38 38 38
PB (FRP-design) 33 33 35
E over-flow valve 97 97 97

(PVC, PP, PVDF) max. 47 47 47
F
(1.4571) max. 52 52 52
valve

H over-flow valve G¾ G¾ G¾
I – centre of overflow valve socket 0 0 0
b Angle, socket overflow valve 90° 90° 90°

J1 (SLA) (max.) 70 70 70
J2 indica-tor 110 110 110
SLA
J3 Electrical actuator 240 240 240
J4 Electrical actuator with PMR3 320 320 320

K2 MBE-03/04 95 95 95
MBE
a Angle MBE-03/04 90° 90° 90°

mechanism the pump

C/CS 409.2

1)
Connection thread G1 for single valves PVC
C 409.2-140
C 409.2-180
C 409.2-250
C 409.2-350
C 409.2-115
C 409.2-18
C 409.2-25
C 409.2-50
C 409.2-75
C 409.2-90
PK (PP-FRP / PVDF-FRP) --- --- 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) --- --- 67 67 75 75 75 75 122 --- 122 ---
Single valves
S 1.4571/1.4581 --- --- --- --- --- --- --- --- 122 --- 122 ---
PK (PP-FRP / PVDF-FRP) 56 56 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) 60 60 67 67 75 75 75 75 152 --- 152 ---
Double valves
1.4571/1.4581 61 61 68 68 76 76 76 76 152 --- 152 ---

PK (PP-FRP / PVDF-FRP) --- --- 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) --- --- 67 67 75 75 75 75 122 --- 122 ---
Single valves
D 1.4571/1.4581 --- --- --- --- --- --- --- --- 122 --- 122 ---
PK (PP-FRP / PVDF-FRP) 64 64 69 69 76 76 76 76 --- --- --- ---
PK (PP / PVDF) 60 60 67 67 75 75 75 75 152 --- 152 ---
Double valves
1.4571/1.4581 61 61 68 68 76 76 76 76 152 --- 152 ---
Connection thread
G Suction/pressure valve G¾ G¾ G¾ G¾ G¾ G¾ G¾ G¾ G1¼ G1 G1¼ G1
A Assembly pump 28 28 37 37 41 41 41 41 58 58
B Centre of valve thread 16 16 15 15 15 15 15 15 30 30

Pump body (PB)
PB (without front plate) 36 36 38 38 37 37 37 37 74 74
C PB (with front plate) 38 38 40 40 39 39 39 39 77 77
PB (FRP-design) 35 35 33 33 33 33 33 33 --- ---

Pump body with integrated over-
E flow valve 97 97 102 102 109 109 109 109 158 158

(PVC, PP, PVDF) max. 47 47 57 57 73 73 73 73 102 102
F
(1.4571) max. 52 52 62 62 77 77 77 77 110 110
valve

H over-flow valve G¾ G¾ G¾ G¾ G1 G1 G1 G1 G1¼ 1)
G1¼ 1)
I – centre of overflow valve socket 0 0 0 0 5 5 5 5 0 0
b Angle, socket overflow valve 90° 90° 90° 90° 90° 90° 90° 90° 45° 45°
J1 (SLA) (max.) 70 70 70 70 70 70 70 70 70 70
J2 indica-tor 110 110 110 110 110 110 110 110 110 110
SLA
J3 Electrical actuator 240 240 240 240 240 240 240 240 240 240
J4 Electrical actuator with PMR3 320 320 320 320 320 320 320 320 320 320
K2 MBE-03/04 95 95 102 102 107 107 107 107 145 145
MBE
a Angle MBE-03/04 90° 90° 25° 25° 25° 25° 25° 25° 70° 70°
mechanism the pump

C/CS 409.2
5.4.2 CS 409.2
H
M8 / Ø 6,5
1
21
80
K2
39
~ 190
47,5
10 80
75 98
194 147,5
min. 200
2
~ 245
~ 160
J3 / J4
I
J2
~ 110
J1
~ 305
32
II
148
X
B
A
C
G
38
E
G
Ø 6,5
D S 78
K1
1 Mounting holes
2 for removing the actuar cover
Drive with electronics can be rotated throughout 90° each and can be put to the positions I and II.
3
(release the motor fastening screws, put the motor carefully to the desired position and fasten with screws again)

C/CS 409.2
CS 409.2-0,8e
CS 409.2-1,6e
CS 409.2-2,4e
CS 409.2-4,0e
CS 409.2-7,0e
CS 409.2-12e
CS 409.2-18e
CS 409.2-25e
Single valves PVC --- --- --- 52 52 52 52 52
PK (PP-FRP / PVDF-FRP) --- --- --- 56 56 56 56 56
S
PK (PP / PVDF) --- --- --- 57 57 60 60 60
Chamber valves
PVC, PP, PVDF, 1.4571 70 70 70 --- --- --- --- ---
Single valves PVC --- --- --- 153 153 153 153 153
PK (PP-FRP / PVDF-FRP) --- --- --- 152 152 152 152 152
D
PK (PP / PVDF) --- --- --- 145 145 148 148 148
Chamber valves
PVC, PP, PVDF, 1.4571 158 158 158 --- --- --- --- ---
Connection thread
G Suction/pressure valve G¾ G¾ G¾ G¾ G¾ G¾ G¾ G¾
A Assembly pump 16 16 16 17 17 14 14 14
B Centre of valve thread 17 17 17 15 15 16 16 16

Pump body
Pump body
(PB)
(PVC, PP, PVDF) 34 34 34 38 38 38 38 38

C
Pump body
(FRP- design) --- --- --- 33 33 33 35 35
E --- --- --- 97 97 97 97 97
PB with ÜV
overflow valve (ÜV)
F Overflow valve socket max. --- --- --- 47 47 47 47 47

Connection thread
H socket overflow valve --- --- --- G¾ G¾ G¾ G¾ G¾
J1 (SLA) (max.) 70 70 70 70 70 70 70 70
J2 indica-tor 110 110 110 110 110 110 110 110
SLA
J3 Electrical actuator 240 240 240 240 240 240 240 240
J4 Electrical actuator with PMR3 320 320 320 320 320 320 320 320
MBE

K1 MBE-02 67 67 67 67 67 67 67 67
mechanism the pump

C/CS 409.2
CS 409.2-4,0
CS 409.2-7,0
CS 409.2-12
CS 409.2-18
CS 409.2-25
Single valves PVC 52 52 52 52 52
S PK (PP-FRP / PVDF-FRP) 56 56 56 56 56
PK (PP / PVDF) 57 57 60 60 60
Single valves PVC 153 153 153 153 153

D PK (PP-FRP / PVDF-FRP) 152 152 152 152 152
PK (PP / PVDF) 145 145 148 148 148
Connection thread
G Suction/pressure valve G¾ G¾ G¾ G¾ G¾
A Assembly pump 29 29 28 28 28
B Centre of valve thread 15 15 16 16 16

Pump body
Pump body
(PB)
(PVC, PP, PVDF) 38 38 38 38 38

C
Pump body
(FRP- design) 33 33 33 35 35
E 97 97 97 97 97
PB with ÜV
overflow valve (ÜV)
F Overflow valve socket max. 47 47 47 47 47

Connection thread
H socket overflow valve G¾ G¾ G¾ G¾ G¾
J1 (SLA) (max.) 70 70 70 70 70
J2 indica-tor 110 110 110 110 110
SLA
J3 Electrical actuator 240 240 240 240 240
J4 Electrical actuator with PMR3 320 320 320 320 320

MBE

K2 MBE-03/04 95 95 95 95 95

mechanism the pump

C/CS 409.2
6. Assembly / Installation
■■ The standard model of the pump is only approved for installation in dry rooms in a non-aggressive atmosphere, at
temperatures between 0°C and 40°C and at permitted humidity until approx. 90%, altitude 1000 m above sea level.
When toxic, crystal-forming or corrosive liquids are being delivered, the pipe system
must be equipped with devices so that it can be emptied, cleaned and, if necessary,
rinsed with a suitable medium.
DANGER!
The dosing pump must be installed in such a way that no damage can be caused if
medium is leaking out.
WARNING!
When the C/CS pump is installed next to a controllable pump a minimum distance of
100 mm between the pumps (motor housings) has to be kept!
ATTENTION!
The pump is designed for operation in non-hazardous areas!
ATTENTION!
■■ Protect the pump against any sources of heat and against the direct irradiation of sun and ultraviolet light.
■■ For dimensions of the pump connections and fixing holes, see Chap. „Dimensiones“.
■■ Install the pump in such a way that there is no vibration and no tension and that it is aligned precisely.
■■ Install the pump at the optimum possible operating height. Mount the pump in such a way that the valves are verti-
cal.
■■ Ensure that there is sufficient space around the pump body and the suction and pressure valve so that these parts
may be easily dismantled, if required.
■■ The stroke length adjustment and indicator scale must be easily accessible and readable.
■■ Design the nominal diameters of the downstream pipes and of the connections built into the system to be the same
size or larger than the nominal inlet and outlet diameters of the pump.
■■ To check the pressure ratios in the pipe system, we recommend to provide for connections for pressure gauges
(e.g. manometers) near the suction and pressure sockets.
■■ Drain cocks are to be provided.
■■ Prior to connecting the pipes, remove the plastic caps on the suction and pressure sockets of the pump.
■■ Check that the fixing screws for the pump body are tightly fitted and, if necessary, retighten (please see Chapter
“Overview of the tightening torques”).
■■ If the pump is equipped with an actuator provide for sufficient space to remove the cover (please see Chapter “Di-
mensions”).
■■ Connect pipes to the pump in such a way that there are no forces acting on the pump, such as e.g. misalignment,
weight or stress of the pipe.
■■ Keep the suction lines as short as possible.
■■ Use pressure- and medium-resistant hoses / pipes.
■■ All pipes and containers connected to the pump must comply with the regulations and must be cleaned, tension-free
and intact.
■■ Mount the pump in such a way that electronics, operating panel and electric connections are easy accessible.
■■ Inlet nominal widths of CS-pumps see chapter „Technical data“.
■■ With CS pumps or pumps with manual venting, connect a hose for reflow of the pumped medium.

C/CS 409.2
In order to avoid cavitation, overloading and excessive delivery, the following points should be noted:
■■ Avoid high suction heights.

■■ Keep pipes as short as possible.
■■ Choose sufficiently large nominal diameters.
■■ Avoid unnecessary choke points.
■■ Install a pulsation damper.
■■ Install a pressure relief.
■■ Install a pressure keeping valve, if necessary.
■■ In the case of degassing media, provide for a supply.
■■ In the case of degassing media, provide for a supply, respectively use the CS-series.
The operator must take suitable precautions on the supply side (collecting tray, dia-
phragm rupture electrode) to ensure that the container does not run dry in the event
of a diaphragm rupture.
WARNING!
Illustrations in this chapter!

The names of the shown modules/components are based
on the following assignment:
NOTE!
1 Dosing pump 12 Tank empty alarm

2 Tank 13 Drain fitting
3 Main line / process line 14 Priming aid / Siphon vessel
4 Suction line 15 Hand vacuum pump
5 Pressure line 16 Pulsation damper
6 Feedback line 17 Flushing medium
7 Check valve 18 Safety valve
8 Vent valve (ball valve) 19 Diaphragm relief valve
9 Injection fitting 20 Pressure keeping valve
10 Shut-off valve 21 Dosing pump with integrated relief valve
11 Strainer 22 Dosing pump CS...

C/CS 409.2
6.1 Provide overpressure protection

If the permissible pressure in the system may be exceeded, e.g. when a shut-off valve is closed or if the line is blocked:
■■ Install the overflow valve (19).

■■ Use sera - diaphragm pump with integrated overflow valve.
10
19
10
5 21
6
6
5
1
2
4 4
When using an external relief valve the following is valid for the feed back pipe:
■■ Lead the overflow line with descending gradient in the store tank which is under atmospheric pressure or in an
open drain gutter.
■■ Or connect the overflow line directly to the pump suction line, but only if there is no check valve inside the suc-
tion line (e.g. foot valve of a suction lance).
10
19 10
5
6 21
5
6
1
4 4

C/CS 409.2
Shut-off valves must not be closed when the pump is running!
ATTENTION!
Provide an overpressure protection (e.g. overflow valve) if the permissible opera-

ting pressure may be exceeded.
CAUTION!
If the permissible operating pressure is exceeded and the pump is not equipped
with an overpressure protection the pump can get damaged.
ATTENTION!
The pumped medium may spout out if the pump is damaged.
DANGER!
6.2 Prevent a backflow of the pumped medium

If the dosing line is linked with a main line:
3
■■ Install an injection fitting (9).

9
There will be an unintentional mix-

ture in the dosing line if a possible
backflow from the main line is not 5 21
prevented.
DANGER!
6
2
Pay attention to / avoid chemical
reactions arising from a backflow of
the pumped medium. 10
DANGER! 4

C/CS 409.2
6.3 Eliminate undesired siphoning

When dosing into a main line with negative pressure:
3
■■ Install a pressure keeping valve (20) into the dosing.
When installing a pressure keeping 9

valve, make sure that an uncon- 20
trolled dosing is prevented (by a
5
positive pressure difference (≥ 1
bar) between pressure and suction
side). 21
ATTENTION!
2
6
10
4
6.4 How to ensure an gas-free suction

If slightly degassing media are conveyed and the medium is pumped in a pressurised pipe or against a pressure
keeping valve:
■■ The CS 409.2 series (22) should be employed.

■■ Install a ventilation valve (8) in the pressure line.
■■ The nominal width of the suction line (14) shall not excced the input nominal width with CS-design.
■■ Consider usable stroke length range with self-ventilation (see chapter „Technical data“).
3
3
9 9
5
5
8
21
22
6
4
4
2
2

C/CS 409.2
The delivery flow may be interrupted if air/gas enters the suction line!
NOTE!
In the case of media which are lightly crystallizing when they come in contact with
air, the return line should be laid with a loop. Thus a contact between the medium
and air in the outlet area of the vent valve is prevented.
NOTE!
6.5 Install the empty-tank alarm

so that the tank is refilled before air is drawn in.
The delivery may be interrupted if 5

air enter in the suction line!
1
NOTE!
12
6.6 How to avoid an emptying of the suction line

■■ Install a foot valve at the end of the suction line.
Based on calculations, the dimension ‘H’ may not exceed the

number that is equal to the specified maximum suction height of
the pump divided by the density of the pumped medium and in
consideration of mass acceleration and viscosity of the medium. 5

C/CS 409.2
6.7 Line strainer

■■ Connect the suction line slightly above the bottom of the tank
and install a line strainer (0.1 – 0.5mm aperture size – depen-
ding on nominal width of the valve).
Pump and system may not function

properly if contami-nates are not
1
collected. 5
ATTENTION!
2
4
11
10
6.8 Suction via a siphon pipe

For use with high tanks without connection on the tank bottom:
■■ Install the siphon vessel

■■ Pay attention to accelerating pressure which may be genera-
ted in a long suction line. 10
15
14
10
4
2
10

C/CS 409.2
6.9 In case of slightly degassing dosing media

■■ Install the pump so that it can be operated with afflux.
■■ Bzw. CS-Ausführung (22) einsetzen.
CS-Ausführung muss immer oberhalb des Behälters montiert werden, damit am

Ausgang der Entlüftungsautomatik kein Gegendruck ansteht.
HINWEIS!
22
5
6
1
2
4 2 4
10
10
6.10 Dosing of suspensions

Pump head must be cleaned to avoid precipitation, e.g. as:
5
■■ intermittent rinsing
or
■■ rinsing when pump was switched off.
1
Rinsing is absolutely required after

the dosing pump was switched off!
ATTENTION!
10
17
2
The rinsing process should be
4
automated.
NOTE!

C/CS 409.2
6.11 Damping of the pulsation

By installing pulsation dampers if:
■■ for procedural reasons, a pulsation-poor flow rate is desired,

■■ accelerating forces which arise due to the pipe geometry must be reduced.
16 5
16 1
2
1
2 4
10 10
4
13
Installation of suction and/or pressure pulsation dampers near the pump head.
■■ If both pulsation damper and pressure keeping valve (20) should be integrated install the pressure keeping valve
between pump and pulsation damper.
16
16
5
5
20
16 1
2
4
2
4
13 10
10

C/CS 409.2
Undamped accelerating forces can cause the following malfunctions / damage:
■■ Fluctuations of the delivery rate,

WARNING! ■■ dosing errors,
■■ pressure thrusts,
■■ valve wobbles,
■■ increased wear on the suction- and pressure side of the pump.
■■ Mechanical breakdown of the pump, leakage and valve wobbles as a result of the
maximum pressure on the pressure side of the pump being exceeded.
■■ Damage to the pipe and in the pipe installed fittings.

C/CS 409.2
7. Electrical connections
7.1 Electric supply

The sera diaphragm pump is delivered ready for installation. Standard delivery includes a 2m power cable with Euro
plug. The standard version C 409.2 is designed for an operating voltage range of 210 – 250 V, 50/60 Hz.
The self-venting version CS 409.2 has a limited operating voltage range. The speci-
fications on the type plate must absolutely be adhered to!
The CS 409.2 is available in three versions:

ATTENTION!
■■ 210 – 250 V, 50/60 Hz
■■ 100 – 120 V, 50 Hz
■■ 100 – 120 V, 60 Hz
Switching the voltage supply on and off temporarily is to be avoided.
ATTENTION!
The pump restarts in the selected operating mode after the power supply was swit-
ched on or a power supply recovery following a mains failure!
ATTENTION!
Symbol:
Only operate the pump when it is connected to an earthed power supply!
ATTENTION!

C/CS 409.2
7.2 Electrical interfaces

The connectors for the electrical interfaces are located on the back of the pump below the control panel.
7.2.1 Control inputs and outputs

The pump is equipped with three control inputs and two control outputs. They can be programmed with different
functions. All three inputs can be used as digital inputs, whereas two of them can optionally be configured as ana-
log inputs (inputs 02 and 03, see Chapter „Digital/analog inputs 02 and 03“). When leaving the factory, the inputs
and outputs are preset as described in table.
Symbol:
Connector socket for

control inputs and outputs
Standard delivery of the dosing pump includes a 5m control cable, which is to be connected to the 8-pin socket of
the control inputs and outputs. Following table shows the identification of the individual leads of the control cable.
Lead Pin Function (ex works setting)

colour
WH (white) 1 Input 01 (pulse)
BN (brown) 2 Input 02 (analogue 01)
GN (green) 3 Input 03 (external ON)
YE (yellow) 4 Output + / signal + / 15 V DC
GY (grey) 5 Output 01 (collective fault)
PK (pink) 6 Output 02 (stroke signal)
RD (red) 7 Ground
BU (blue) 8 Ground
The digital inputs can not only be switched by a potentialfree contact signal but also directly via a control voltage
signal (e.g. 24V DC) (see Fig. „Control of digital inputs via a potential-free contact signal“).
This enables, for example, the direct connection of a programmable logic controller to the dosing pump.
When an external supply (for example, 24 V DC) is con-nected to the pin output
+ (colour of cable lead: yellow) the following has to be considered:
A protective diode is necessary in the feeding pipe of the external supply in or-
der to exclude a feeding back of the pump (see fig. „Direct activation of digital
ATTENTION! inputs via a control voltage signal of a programmable logic controller“).
Connect the anode with 24V DC.
Connect the cathode with the yellow lead of a cable.
Use the diode type 1N4007 or the like.

C/CS 409.2
Following fig. shows exemplarily the control of the digital inputs 01 and 03 via a potential-free contact signal.
The outputs 01 and 02 are not potential-free! In order to enable a potential-free

switching via the outputs, the use of a relay is necessary.
ATTENTION!
Fig: „Control of digital inputs via a potential-free contact signal“
RD + BU
-
PK
GY Collecting Fault (15V DC) +
YE
GN Extern Stop
BN
Contact signal
WH Pulse
Contact signal
The maximum voltage/maximum current withstand capability of the control

inputs and outputs is as follows:
Inputs: 30V DC / 50mA

ATTENTION! Outputs: 15V DC / 50mA (internal supply)
30V DC / 350mA (external supply)
The output + / signal + connection pin (lead colour: yellow) is not short-circuit
proof! In case of a short-circuit, the control electronics may get damaged!
Therefore, please make absolutely sure that the signal + connection pin is not
ATTENTION! directly connected with the earth connections (lead colour: red and blue)!

C/CS 409.2
Following Fig. shows exemplarily the direct activation of the digital inputs 01 and 03 via a control voltage signal (in
this example: 24V DC) of a programmable logic controller.
Fig.: „Direct activation of digital inputs via a control voltage signal of a programmable logic controller“
Pragrammable
Logic Controller
(PLC)
RD + BU
0V (Ground)
PK
GY Collecting Fault
Input
Diode 1N4007 o.ä.

YE Cathode Anode
24V DC
GN Extern Stop
24V DC (Output)
BN
WH Pulse
24V DC (Output)
7.2.2 Level input with pre-alarm and dry run
Pre-alarm and dry run are connected to the same jack. When leaving the facto-
ry, both inputs are preset to “closing when floating down”.
However, if necessary, they can be freely configured
NOTE! (see Chapter „Level monitoring“).
Symbol:
Jack for level input
Suction lances that are compatible with types R/C 203 or C 408.1/409.1 can be connected to the pump using an
adapter plug M8/M12, 3-pin (Item No. 90025005).

C/CS 409.2
7.2.3 Input for flow control and flow meter
Only flow controllers and flow meters made by sera may be connected to the
dosing pump.
If you use other than sera products, the electronics might get damaged.
ATTENTION!
Symbol:
Jack for flow control /flow meter
sera flow controllers and flow meters are delivered completely with cable and plug. Electrical connection is made
directly to the 5-pin socket.
sera flow controllers that are compatible with types R/C 203 or C 408.1/409.1 can be connected to the pump using
an adapter plug M8/M12, 4-pin (Item No. 90025006).
8. Operation in non-hazardous areas
Die pumpe ist nur für den Betrieb außerhalb des Ex-Bereiches ausgelegt!
ACHTUNG!

C/CS 409.2
9. Start-Up
9.1 Driving Motor

Preconditions:
Make sure that voltage and frequency correspond with the indications on the type plate of the motor.
Permissible voltage tolerance (DIN VDE 0530)
for rated voltage + 10 %

for rated voltage range ±5%
The connecting cable must be dimensioned according to the motor characteristics.

Secure connecting cable with a strain relief.
The nominal motor power refers to an ambient temperature of 40°C and an installation site below 1000m above sea
level. Motor output will be reduced if these values are exceeded (see VDE 0530).
Adapted for “moderate” groupe of climates according to IEC 721-2-1.
The drive motor will heat by operation of the pump.

Do not touch the motor during operation!
NOTE!
9.2 Initial start / Restart

Controls for start-up
■■ Check whether all connections for tightness; if applicable, retighten.

■■ Check that the fixing screws for the pump body are tightly fitted and, if necessary, retighten
(see table Chap. „Overview of the tightening torques“).
■■ Check whether all electrical connections are correct.
■■ Check whether the information of the mains voltage on the type plate with the local circumstances agrees.

C/CS 409.2
10. Operation
10.1 Operating elements
2
5
1 6
1 STOP/START-Button
2 LED-Indication
3 LCD-Display
4 UP-Button
5 DOWN-Button
6 ENTER-Button
10.2 LED operation indicators

Three light-emitting diodes (LED) indicate the status of the pump:
Green: Operation and stroke indicator

When switching on the pump, the green LED lights steadily. The operation indicator works in combination
with a stroke indicator; during pump operation, the LED flashes in accordance with the current stroke
frequency.
Yellow: Warning indicator

The yellow LED indicates all occurring warning messages (see following Tab). The warning is not only
indicated by the LED but also as plain text in the LCD display
Red: Fault indicator

The red LED indicates all occurring faults (see following Tab.). The fault is not only indicated by the LED
but also as plain text in the LCD display.

C/CS 409.2
Overview of LED indicators

Green LED Yellow LED Red LED
Ready ON
Stroke confirmation flashing
Internal error ON
Supply voltage too low / too high ON
No mains
Level monitoring
Level pre-alarm flashing
Dry run flashing
Dosing control (flow controller or flow meter)
No flow - with warning message ON
No flow- with shut-off ON
Flow too low- with warning message ON
Flow too low - with shut-off ON
Optional diaphragm rupture monitoring
Diaphragm rupture ON
Vent valve (CS 409.2)
Venting flashing ON
Analog mode
mA signal < 3,5 mA ON
mA signal > 20,5 mA ON
The “dry run” fault message suppresses the “pre-alarm” warning. This means that
if the pump runs dry while the 2-stage level monitoring is activated, then only the
red LED will flash.
NOTE!
10.3STOP
Key operation
START
Operation of the pump is performed with 4 keys:
STOP
STOP/START key
START After connection to the power supply, the pump is switched ON/OFF using the STOP/START
STOP key.
START
ENTER
ENTER key
You can use the ENTER key to open and confirm value input fields and to select menu items.
ENTER
ENTER
UP / DOWN key
Using the UP/DOWN key, you can scroll the different menu items / menu levels and select the
display of various operating messages.
During parameter adjustment, the UP key is used to increase the parameter value and the
DOWN key is used to decrease the parameter value.

C/CS 409.2
10.4 Parameter table

Following table shows the factory settings of the controllable diaphragm pump. With these defaults, the user can start
standard applications such as manual operation, analog operation with 4-20mA, 1/1 pulse operation and external ope-
ration with External ON, without having to make further adjustments. It is only necessary to select the operation mode
from the respective menu (see Chapter „Selecting the operation mode“) and, in case of external control, to connect
the respective input (see Chapter „Control inputs and outputs“).
The references to the respective chapters facilitate the adjustment of the settings to special applications and dosing
tasks.
In addition, the parameter table offers the possibility to document the changes that have been made in the settings.
Thus, the current settings of the pump can be viewed quickly at any time.
Overview of preset parameters

Factory settings Chapter Adjustment Modification 1 Modification 2
Impulsbetrieb
Pulse mode 1/1 10.7.2
Pulse factor 1 10.7.2
Pulse memory ON 10.7.2
Analog mode
Analog mode Auto 10.7.1
Analog signal 4-20mA 10.7.1
Adjustment: Analog I1 4mA 10.7.1
Adjustment: Frequency f1 0% 10.7.1
Adjustment: Analog I2 20mA 10.7.1
Adjustment: Frequency f2 100% 10.7.1
Batch mode
Batch control manual 10.7.3
Batch quantity 100% 10.7.3
Batch start 1min 10.7.3
External mode
Stroke freq. 100 % 10.7.4
Input 01
Function E1 Pulse 10.8.1
Contact E1 NO 10.8.1
Input 02
Function E2 Analog 01 10.8.2
Input 03
Function E3 External ON 10.8.2
Output 01
Function A1 Collective fault 10.8.3
Contact A1 NC 10.8.3
Output 02
Function A2 Stroke signal 10.8.3
Contact A2 NO 10.8.3
Dosing monitor.
Sensor OFF 10.15.2
Function Message 10.15.2
Fault stroke 10 10.15.2
Alarm limit 80 % 10.15.2

C/CS 409.2
Overview of preset parameters

Factory settings Chapter Adjustment Modification 1 Modification 2
Level
Pre-alarm NO 10.15.4
Dry run NO 10.15.4
System
Language English 10.11
Calibration OFF 10.11
SLOW-Mode
Slow-Mode OFF 10.15.1
Speed 80% 10.15.1
Password
PW01-Mode OFF 10.13
Password 01 9990 10.13
Password 02 9021 10.13
Diaphragm rupt. (1)
Input signal NO 10.15.3
Sensitivity 50% 10.15.3
Venting (2)
Venting control OFF 10.15.5

Venting time 10 sec 10.15.5
Interval time 40 min 10.15.5
(1)
only with MBE option (2)
only with CS

C/CS 409.2
10.5 Menu
You can switch between the following three screens:
■■ Operating messages,
■■ Main menu and
■■ Fault and warning messages.
A change to the screen “Fault and warning messages” is only possible when a fault or warning is present.
A change between the screens “Operating messages” and “Main menu” is done by simul- ---MAINMENU---
taneously pressing the UP and DOWN keys. OPERATION MODE
A change between the screens “Operating messages” and “Fault and warning messages” +
is done by simultaneously pressing the ENTER and DOWN keys.
: MANUAL S
63 % freq.
ENTER +
Diaphragm rupture!
After, in the main menu, no key has been pressed for

3 min. the screen “Operating messages” is automatically displayed.
NOTE!
10.5.1 Screen “Operating messages”

Display of current mode
: MANUAL S Flow indicator : BATCH Man.

63 % freq. V 10.34 l
Display of operating messages V: preset dosing quantity

R: remaining dosing quantity
Display of the current operation mode
The first line in the screen “Operating messages” shows the currently set operation mode.
Flow indicator
A star-symbol (*) in the first line on the right-hand side is used as flow indicator. The star symbol indicates the
response of a connected dose monitoring instrument (flow control or flow meter).
The flow indicator (*) is only active when a flow control / flow meter is con-
nected and the dosing monitoring is activated (see Chapter . „Slow-Mode“).
NOTE!

C/CS 409.2
Display of operating messages
The second line of the display shows, dependent on the set operation mode, a variety of operating messages (e.g.
the current stroke frequency, total strokes – see Tab). The operating messages can be scrolled using the UP and
DOWN keys.
You can use the ENTER key to open the value input fields of the editable operating messages (see Tab.). The
value input is described in Chapter „Value entry“.
Operating messages in dependence on the selected operation mode

Operating messages Operation mode
External
Manual
Analog
Batch
Pulse
Current stroke frequency (1)
Current dosing performance (2)
Total strokes
Total dosing quantity (2)
Venting ON/OFF (3)
Current control current
Pulse factor
Memory
Dosing quantity / strokes
Remaining dosing quantity / remaining strokes
Manual start
= Indication
= Indication and setting option

(1)
= not with a calibrated pump
(2)
= only with a calibrated pump
(3)
= only with CS
10.5.2 Fault and warning messages

When a fault or warning has occurred, the dosing pump shows a message in plain text format on the LCD display:
The message disappears automatically when the cause of the fault or warning
has been eliminated.
NOTE!

C/CS 409.2
10.5.3 Screen “Main menu”

The upper line shows the superordinate menu items or editable
parameters. The lower line shows the subordinate menu items
or selectable values and settings.
Superordinate menu items are marked with “---“. Superordinate Example for the display of
means that no values or settings can be assigned to this item. superordinate menu items
It is, for example, possible to select a variety of subordinate
menu items (e. g. ANALOG MODE) in the ---PARAMETER--- ---MAINMENU--- ---PARAMETER---
menu but these items cannot be assigned to the superordinate OPERATION MODE ANALOG-MODE
menu as a fixed value.
Parameters which can be assigned different values or settings

are marked with “>“ and “<“. Such parameters are, for example,
Example for the display of parameters
the operation mode, the analog signal or the pulse mode. Each
parameter should be assigned a definitive value or setting. >OPERATION MODE< >ANALOGSIGNAL<
The >OPERATION MODE< can, for example, be assigned the ANALOG 4-20mA
ANALOG setting.
10.5.4 Value entry

The assignment of values and settings to a parameter is described in the following, using two exemplary illustra-
tions.
Assignment of settings
Example:
Selection of
operation mode
■■ Display of the current setting (in this example: MANUAL operation mode). >OPERATION MODE<
MANUAL
■■ Value entry is enabled after pressing the ENTER key. ENTER
>OPERATION MODE<
MANUAL
■■ Then, the operation mode indicator flashes and a setting can be selected (in this select
example: operation modes) using the UP and DOWN keys. operation
mode
>OPERATION MODE<
ANALOG
ENTER
■■ After a setting has been selected (in this example: ANALOG mode), pressing the
ENTER key will confirm and save the choice.
>OPERATION MODE<
save . . .
■■ Display of the current setting (in this example: ANALOG mode). >OPERATION MODE<
ANALOG

C/CS 409.2
Assignment of values
Example:
Selection of the
pulse factor in
case of division
■■ Display of the current value (in this example: pulse factor 1/1). >PULSE FACTOR<
1/1
■■ Value entry is enabled after pressing the ENTER key. ENTER
■■ Then, the first digit of the pulse factor flashes. >PULSE FACTOR<
01/1
■■ The desired figure can be set using the UP and DOWN keys (in this example: 1). select digit
■■ After having selected the desired figure, pressing the ENTER key will confirm the
ENTER
choice.
■■ Then, the second digit of the pulse factor starts to flash. >PULSE FACTOR<
1 1/1
■■ After having selected the desired figure, pressing the ENTER key will confirm the ENTER
choice.
Then, the third digit of the pulse factor starts to flash. >PULSE FACTOR<
10 /1
■■ After having selected the desired figure, pressing the ENTER key will confirm the ENTER
choice.
■■ Afterwards, the entered value will be saved.

>PULSE FACTOR<
save . . .
■■ Display of current value (in this example: pulse factor 100/1). >PULSE FACTOR<
100/1
The value entry (flashing indication) can be exited by simultaneously pressing the UP and DOWN keys. In this
case, the previous value / previous setting will be maintained.
If, during the value entry (flashing indication), no key has been pressed for 30
sec. the entry mode is exited automatically and the previous value / previous
setting is maintained!
NOTE!

STOP STOP
START START
C/CS 409.2
ENTER ENTER
10.5.5 Menu guide STOP

START
Operation menu e.g. current stroke frequency (depending on chosen operation mode)
STOP
START
+ ENTER
STOP
START
PW01 STOP STOP
START START ENTER
Main menu
ENTER
Manual STOP
START
Pulse
>Operation
Operation mode ENTER ENTER Analog
STOP mode<
STOP STOP STOP
Batch
START START START START
Extern
ENTER
STOP STOP STOP
START START START
ENTER ENTER ENTER ENTER

STOP
PW02 START
Parameter ENTER Pulse mode ENTER >Pulse mode< ENTER

STOP STOP
1/1 START
START
Division
ENTER Multiplication
STOP
START
>Pulse factor< ENTER

STOP present value 0...999
ENTER
STOP
START START
ENTER
STOP STOP STOP
START START START
>Pulse ENTER ENTER

STOP STOP STOP
memory< OFF START
START START
ENTER ENTER ON ENTER

STOP STOP
START START
>Analog-
Analog mode ENTER ENTER
STOP
ENTER
mode< Stroke frequency
START
ENTER Auto ENTER
>Analogsignal< ENTER
STOP STOP
4-20mA
START START
0-20mA
Adjustment
STOP
START
present value
Adjustment ENTER >Analog I1< ENTER
STOP
in mA
START
present value
>Frequency f1< ENTER
STOP
in %
START
present value
>Analog I2< ENTER
in mA
present value
>Frequency f2< ENTER
in %
A1 A2
PW01 Locking by password 01 (pre setting ex work: 9990, not activated)

PW02 Locking by passwordt 02 (pre setting ex work: 9021)

Controllable diaphragm pump STOP
START
STOP STOP
C/CS 409.2 START START
Operating instructions STOP STOP

ENTER
START START
A1 A2 ENTER
STOP
ENTER
START
Batch
STOP mode ENTER >Batch control< ENTER
STOP
START
Manual
START
Pulse Input
ENTER Timer
STOP
START
>Batch
ENTER ENTER
STOP present value
quantity<
START
ENTER
>Stroke freq.< ENTER

STOP present value in % STOP
START START
STOP STOP
STOP STOP START STOP START STOP
STOP STOP >Batch start< ENTER

STOP present value in hh:mm
ENTER
START START START
STOP
Extern mode ENTER >Stroke freq.< ENTER present value in % START
ENTER ENTER ENTER ENTER
STOP
Pulse
In-/Output ENTER Input 01 ENTER >Function E1< ENTER START
Extern ON
Extern stop ENTER
STOP STOP
De-aeration 1)
START START
Batch start
Analog 01/02ENTER
OFF
STOP STOP STOP
START START START
STOP >Contact E1< ENTER

STOP
ENTER
START START NC
NO STOP
START
ENTER ENTER ENTER
STOP
Pulse
Input 02 ENTER >Function E2< ENTER START
Extern ON
Extern stop ENTER
STOP STOP
De-aeration 1) START
START
Batch start
Analog 01 ENTER
OFF
STOP STOP STOP
START START START
STOP >Contact E2< ENTER

STOP
ENTER
START START NC
NO STOP
START
ENTER ENTER ENTER
STOP
Pulse
Input 03 ENTER >Function E3< ENTER START
Extern ON
Extern stop ENTER
STOP
De-aeration 1)
START
Batch start
Analog 02 ENTER
OFF
>Contact E3< ENTER
NC
NO
B1 B2

Controllable diaphragm pump STOP
START
STOP STOP STOP
C/CS 409.2 START START START
Operating instructions STOP STOP

ENTER
START START
ENTER ENTER ENTER

B1 B2
Ready to run
Output 01 ENTER >Function A1 ENTER
Collecting fault
STOP
Stroke signal
START
Pre-alarm level
Dry-run
STOP
Diaphragm START
rupt. 2)
Batch finished ENTER
STOP STOP
Internal error START
START
No flow
OFF ENTER
STOP
STOP
START
Collect. signal
START
STOP >Contact A1< ENTER

STOP
ENTER
NC
START START
ENTER
NO ENTER
Ready to run
Output 02 ENTER >Function A2< ENTER
Collecting fault
STOP
Stroke signal
START
Pre-alarm level
Dry-run
STOP
Diaphragm START
rupt. 2)
Batch finished ENTER
STOP STOP
Internal error START
START
No flow
OFF ENTER
STOP STOP STOP STOP
START START START
Collect. signal
START
STOP STOP >Contact A2< ENTER

STOP
ENTER
NC
START START START
ENTER ENTER ENTER NO ENTER

STOP
START
>SLOW-
Extras ENTER SLOW-MODE
STOP ENTER STOP ENTER
STOP STOP
START
MODE<
START
ON START
START
OFF ENTER
STOP STOP
START START
>Driving
ENTER ENTER ENTER preset valueENTER
30-100%
speed< STOP
START
OFF
Dosing monitor. ENTER >Sensor<
STOP
ENTER
Typ 8015.1 STOP
START START
Typ 8014.1
Typ 8013.1 ENTER
STOP Typ 8012.1
START
Typ 8011.1
ENTER
Typ 8010.1 ENTER
STOP
Typ 819x
START
>Function< ENTER
STOP
Dosing stop
START
ENTER Message
>Fault stroke< ENTER preset value
C1 C2 C3

STOP
C/CS 409.2 START
Operating instructions STOP

START
C1 C2 ENTER C3 STOP
START
STOP >Alarm
STOP limit< ENTER
STOP preset valueSTOP
in %
ENTER
STOP STOP
START START
ENTER Calibration
ENTER ENTER
Calibration of dosing pump
ENTER
Press ENTER (see chap. Calibration“)
STOP
START
Diaphragm ENTER >Input signal< ENTER

STOP
rupt. 2)
STOP STOP OFF STOP
START
START START
NC START
NO
ENTER
STOP
STOP STOP
START START
START
ENTER >Sensitivity<
ENTER
ENTER preset valueENTER
in %
STOP
START
ENTER
Level ENTER >Pre-alarm< ENTER
STOP
OFF
STOP
START START
NC
NO ENTER
STOP STOP
START START
STOP >Dry run< ENTER

STOP
ENTER
OFF
START START
NC
ENTER NO ENTER
STOP
START
De-aeration 1) ENTER >Control< ENTER

STOP OFF
START Automatic
Interval
ENTER
Extern
>De-aeration ENTER
STOP preset value in s
time<
START
>Interval time< ENTER preset value in min
D1

STOP STOP
START START
C/CS 409.2
STOP
START
ENTER ENTER
STOP
D1 START
Totalizer ENTER Total quantity
ENTER
STOP Total strokes

START
STOP STOP
START START
ENTER
STOP Operation
STOP hours STOP
START START START
Calibration of dosing pump

Calibration ENTER
STOP STOP
ENTER
STOP
(see chap. Calibration“) START
START START
ENTER ENTER
STOP ENTER
STOP
START START
System ENTER >Language< ENTER

STOP
ENTER
STOP
German START
START
English
ENTER
STOP
Spanish ENTER
STOP
START START
ENTER
>Calibration< ENTER
STOP
ON
START
ENTER OFF ENTER

STOP
START
STOP >Factory
STOP reset< ENTER
STOP STOP
START START
YES START
START
NO ENTER
STOP STOP
START START
ENTER
>System
ENTER
STOP time< ENTER preset valueENTER
in hh:mm
START
Password ENTER >PW1-mode< ENTER

STOP
ON
START
ENTER OFF
>Password
STOP 01< ENTER
STOP preset value (99903))
START START
STOP
START
>Password 02<
ENTER ENTER preset value (90213))
Info ENTER HW-Version
SW-Version
1)
only CS 409.2
2)
only with option MBE
3)
pre setting ex work

C/CS 409.2
10.6 Selecting the operation mode

You can select among five different operation modes:
■■ MANUAL
■■ PULSE
■■ ANALOG
■■ BATCH
■■ EXTERNAL
On-site operation and on-site control of the pump without external control. The flow rate >OPERATION MODE<
can be set via the manual stroke length adjustment and/or by presetting a stroke fre- MANUAL
quency. With a calibrated pump, the delivery rate is set in l/h instead of via the stroke
frequency.
The pump is released or blocked via an external switch. If the pump is released, it will run >OPERATION MODE<
at the preselected stroke frequency (see Chapter „Settings for the EXTERNAL operation EXTERN
mode“).
Batch dosing that can either be started manually, via an external pulse signal or by time >OPERATION MODE<
control. The batch quantity can be entered in strokes or in liters (only with a calibrated BATCH
pump) (see Chapter. „Additional settings for the BATCH mode“).
The stroke frequency of the pump is controlled via the received analog signal. The pump >OPERATION MODE<
can optionally be controlled with a control current of either 0…20mA or 4…20mA. ANALOG
In addition, there is the possibility to adjust the receiving analog signal according to needs
(see Chapter. „Additional settings for the ANALOG operation mode“):
Three pulse modes are offered. The pump can either be operated in the 1/1 mode or
>OPERATION MODE<
with multiplication or division of the input pulses (see Chapter. „Additional settings for the
PULSE
ANALOG operation mode“).
Setting diagram
■■ Go to the ---MAIN MENU--- and select the menu item OPERATION MODE ---MAINMENU---
(if necessary, use the UP / DOWN keys). OPERATION MODE
■■ Pressing the ENTER key will open the >OPERATION MODE< submenu. ENTER
■■ Here, the currently set operation mode is indicated (in this example: MANUAL). >OPERATION MODE<
MANUAL
The adjustment of an operation mode is done in accordance with the description in Chap-
ter „Value entry“.

C/CS 409.2
10.7 Additional settings for the operation mode

Depending on the selected operation mode, specific settings can be made.
■■ Go to the ---MAIN MENU--- and select the menu item PARAMETER (if necessary, ---MAINMENU---
use the UP / DOWN keys). PARAMETER
■■ Pressing the ENTER key will open the --- PARAMETER --- submenu. ENTER
■■ Here, the currently set operation mode is indicated in this example: ANALOG
---PARAMETER---
MODE).
ANALOG-MODE
select
■■ The DOWN key is used to move to the respectively next operation mode. operation
The UP key is used to move to the previous operation mode. When in the PULSE mode
MODE, the UP key is used to move back to the ---MAIN MENU---.
ENTER
After having selected the operation mode, the ENTER key can be used to move to the specific settings for the se-
lected operation mode.
In the ---PARAMETER--- menu, there is no adjustment possibility for the MANUAL

operation mode.
NOTE!
10.7.1 Additional settings for the ANALOG operation mode
In order to be able to use the ANALOG operation mode, at least one input must
be assigned the ANALOG 01 or ANALOG 02 function (see Chapter „Digital/ana-
log inputs 02 and 03“).
Input 02 (see Chapter „Control inputs and outputs“) is factory preset to analog
NOTE! input (ANALOG 01).
Choose the ANALOG MODE
Two different analog modes can be chosen:
■■ Auto
■■ Stroke frequency
>ANALOG-MODE<
The motor speed is adjusted corresponding to the stroke frequency. If the stroke fre-
AUTO
quency falls below 30% operation changes to Stop&Go.
Stop&Go operation covering the whole stroke frequency range, that means every
>ANALOG-MODE<
stroke is performed with full motor speed. STROKE FREQUENCY

C/CS 409.2
Selecting the ANALOG SIGNAL
You can select among three different analog signals.
■■ 4-20mA
■■ 0-20mA
■■ ADJUSTMENT
A signal with a control current of 4mA corresponds to 0% stroke frequency; a signal

>ANALOGSIGNAL<
with 20mA corresponds to 100% stroke frequency. In this range, the stroke frequency
4-20mA
behaves proportionally to the control current (see following Fig.).
If the input signal is < 3.5mA, then the pump emits the error message “Analogsignal <
4mA“. Thus, a wire breakage (control current = 0mA) can be detected.
If the input signal is > 20.5mA, then the pump stops and the error message “Analog-
signal > 20 mA“ is emitted.
A signal with a control current of 0mA corresponds to 0% stroke frequency; a signal >ANALOGSIGNAL<
with 20mA corresponds to 100% stroke frequency. In this range, the stroke frequency 0-20mA
behaves proportionally to the control current (see following Fig.).
100
stroke frequency [%]
80
60
0-20m A
40
4-20m A
20
0
0 4 8 12 16 20
current [mA]
The anlog control signal can be adjusted according to needs. This is, for example,
necessary if a connected regulator provides a limited output signal. >ANALOGSIGNAL<
Two points are given that reflect a proportional relation between control current and ADJUSTMENT
stroke frequency of the pump. In addition, these two points restrict the stroke frequen-
cy range of the pump as shown in the following Fig.
Example: adjustment of the analog signal
■■ Point 1: 15% stroke frequency at 5mA

■■ Point 2: 80% stroke frequency at 15mA
If the control current is < 5mA, then the stroke frequency of the pump is 0%.
If the control current is > 15mA, then the stroke frequency of the pump is 80%:
100
2
stroke frequency [%]
80
60
40
20 1
0
0 4 8 12 16 20
current [mA]

C/CS 409.2
If the input signal is greater than 25 mA, the pump stops and a fault indicator
„analog signal > 25 mA“ is emitted. Additionally in this case, the appropriate in-
put will be switched off as protective measure. The input is reactivated after the
ATTENTION! dosing pumps is switched off and started again via the button STOP/START.
Fig.: „Connection of two analog signals with switch-over“
RD + BU mA-SIGNAL 1 (-)
mA-SIGNAL 2 (-)
PK
GY
YE
GN
mA-SIGNAL 2 (+)
BN
mA-SIGNAL 1 (+)
WH
ANALOG 01/02

C/CS 409.2
ADJUSTMENT of the analog signal
The adjustment of the analog signal is done under consideration of two default points. These two points are two
value pairs which assign control currents to stroke frequencies:
■■ Point 1 (I1, f1)

■■ Point 2 (I2, f2)
The following diagram shows the procedure to determine the points:

Setting diagram
■■ Go to the ---PARAMETER--- menu and select the ANALOG MODE menu item ---PARAMETER---
using the ENTER key. ANALOG-MODE
ENTER
■■ Use the DOWN key to skip the selection of the ANALOG SIGNAL. >ANALOGSIGNAL<
4-20mA
■■ Select the ---ADJUSTMENT---submenu using the ENTER key. ---ADJUSTMENT---
ENTER
■■ Enter the value for current I1.To do so, proceed as described in Chapter „Value
>ANALOG I1<
entry“. . mA
preset value
>FREQUENCY f1<
■■ Enter the value for stroke frequency f1 which is assigned to current I1. To to so, %
proceed as described in Chapter. „Value entry“.
preset value
■■ Enter the value for current I2. To do so, proceed as described in Chapter „Value >ANALOG I2<
entry“. . mA
preset value
■■ Enter the value for stroke frequency f2 which is assigned to current I2. To to so, >FREQUENCY f2<
proceed as described in Chapter „Value entry“. %
preset value
■■ The adjustment is then completed. ---ADJUSTMENT---

C/CS 409.2
10.7.2 Additional settings for the PULSE mode
In order to be able to use the PULSE operation mode, at least one input must
be assigned the PULSE function (see Chapter „Configuring the inputs and
outputs“).
Input 01 (see Chapter „Control inputs and outputs“) is factory preset to pulse
NOTE! input (ANALOG 01).
Selecting the PULSE MODE
You can select among three different pulse modes:
■■ 1/1
■■ DIVISION
■■ MULTIPLICATION
In this mode, the pump performs exactly one stroke for each received pulse. >PULSE MODE<
1/1
In this mode, a division of the received pulses is performed. This means that a stroke >PULSE MODE<
will only be performed after an adjustable number of pulses (division factor) has been DIVISION
received.
In this mode, a multiplication of the received pulses is performed. This means that the >IMPULSMODUS<
pump will perform an adjustable number of strokes (multiplication factor) after every MULTIPLICATION
received pulse.
Selecting the PULSE FACTOR
Depending on the selected pulse mode, the pulse factor corresponds either to the division factor or the multipli-
cation factor.
The division factor can be selected between 1 and 999. If, for example, the division >PULSE FACTOR<
factor is 50, then the pump will perform a stroke only with every 50th received pulse. 50/1
The multiplication factor can be selected between 1 and 999. If, for example, the
multiplication factor is 50, then the pump will perform 50 strokes with every received >PULSE FACTOR<
pulse. 1/50
For setting the pulse factor, please see the description in Chapter „Value entry“ (As-
signment of values).
Switching ON/OFF the PULSE MEMORY
The pump is equipped with a pulse memory, which can optionally be switched ON and OFF. 999 strokes max can
be saved.
If the number of received pulses exceeds the number that can be handled by the pump, then the pulses will be
buffered and the strokes will be performed later.

C/CS 409.2
Example: With the setting 1:50, 5 pulses are in the memory ► perform. of 5 x 50 strokes = 250 strokes.
Fig.: „Connection of a pulse signal with External stop and response of the stroke signal“
RD + BU
PK
GY Collecting fault
15 V DC
YE
GN Extern Stop
BN
Contact signal
WH Pulse
Contact signal
10.7.3 Additional settings for the BATCH mode

Selecting the type of CONTROL
You can select among three different types of control:
■■ MANUAL
■■ TIMER
■■ PULSE INPUT
With this type of control, the batch is started manually in the “operating messages” >CHARGE CONTROL<
screen by pressing the ENTER key. MANUAL
With this type of control, the batch is started daily at a fixed adjustable time (system >CHARGE CONTROL<
time of the pump). TIMER
The pump starts the batch when the preset time matches the system time of
the pump. When the supply voltage is switched off, then the system time will
be reset to 0:00.
ATTENTION!
If the TIMER control is set, then the batch dosing will be repeated daily at the
set time.
ATTENTION!
With this type of control, the batch is started via an external pulse at the pulse input. >CHARGE CONTROL<
PULSE INPUT

C/CS 409.2
In order to be able to use the PULSE INPUT control, at least one input must be
assigned to the START BATCH function (see Chapter „Configuring the inputs
and outputs“
NOTE!
Determining the BATCH QUANTITY
The type of entry for the batch quantity depends on the calibration (see Chapter „Calibration“):
■■ Entry in strokes if the pump is not calibrated

■■ Entry in liters if the pump is calibrated
Adjusting the STROKE FREQUENCY
The stroke frequency at which the pump works during batch dosing can be adjusted.
The value input is described in Chapter „Value entry“.
Determining the BATCH START
The pumps starts the batch dosing when the system time of the pump matches the >BATCH START<
value entered under BATCH START. 16:30 h
The value input is described in Chapter „Menu guide“.
In order to enable time-controlled batch dosing, TIMER control must be set

under BATCH MODE.
NOTE!
Fig.: „Possible connector pin assignment in batch mode“
RD + BU
PK
GY Batch finished
15 V DC
YE
GN
BN
WH Batch start
Contact signal

C/CS 409.2
10.7.4 Settings for the EXTERNAL operation mode
In order to be able to use the EXTERNAL operation mode, at least one input
must be assigned the EXTERNAL ON function (see Chapter „Configuring the
inputs and outputs“).
Input 03 (see Chapter „Control inputs and outputs“) is factory preset to Exter-
NOTE! nal ON.
In the EXTERNAL operation mode, only one stroke frequency (e.g. 63%) can be set. >STROKE FREQ.<
As soon as an external ON signal is received, the pump will start running at this stroke 63 %
frequency.
The value input is described in Chapter „Menu guide“.
Fig.: „Possible connector pin assignment in External operation mode“
RD + BU
PK
GY Stroke signal
15 V DC
YE
GN Extern ON
BN
Contact signal
WH
10.8 Configuring the inputs and outputs

The pump is equipped with three inputs and two outputs, which can be configured via a menu and thus be adapted
to the given operating conditions.
It is possible to assign the same functions to all three inputs.
If several inputs are configured identically, then the input signals will be evaluated
via OR-operation. This means that the function will be performed as soon as one of
the inputs fulfils the condition.
NOTE! Exception: Pulse input with pulse memory. If the pulse memory is switched on, then
the received pulses will be summed up.

C/CS 409.2
Setting diagram
---MAINMENU---
IN- /OUTPUT
■■ Go to the ---MAIN MENU--- and select the menu item IN-/OUTPUT
ENTER
(if necessary, use the UP / DOWN keys).
■■ Pressing the ENTER key opens the ---IN-/OUTPUT--- submenu.
--IN- /OUTPUT--
INPUT 01
Here, you can select among the individual inputs and outputs.
ENTER
Pressing the ENTER key opens the menu level for setting the individual inputs and out-
puts.
>FUNCTION E1<
OFF
preset value
--IN- /OUTPUT--
10.8.1 Digital input 01

Input 01 can be assigned one of six different functions. Optionally, it can also be switched off.
■■ Pulse
■■ External On
■■ External Stop
■■ Venting (only with the “venting” option!)
■■ Batch Start
■■ Analog 01/02
■■ OFF
In addition, it is possible to configure the contact signal of the input as NC or NO.
Configuration of the respective input as pulse input.

>FUNCTION E1<
PULSE
Function for externally switching on the pump via the respective input (only with the >FUNCTION E1<
EXTERNAL operation mode). EXTERN ON
Function for externally switching off the pump via the respective input (independent of >FUNCTION E1<
the operation mode). EXTERN STOP
If the dosing pump is switched off via External Stop, then an “S” will be indica-
ted in the 1. line of the display on the right-hand side:
: MANUAL S
NOTE! 63 % freq.

C/CS 409.2
Function for the external control of the venting automatic via the respective input; this >FUNCTION E1<
automatic is only installed in the self-venting version CS. DE-AERATION
Function for externally starting the batch via the respective input. >FUNCTION E1<
START BATCH
This function is used to switch over between the two analog inputs Analog 01 and >FUNCTION E1<
Analog 02 (input 02 and 03) via input 01. Selection of the analog input is done in ac- ANALOG 01/02
cordance with the following Table.
Analog input switchover

Configuration Contact E1 Applied signal Selected analog input
NC High Analog 01 (input 02)
NC Low Analog 02 (input 03)
NO High Analog 02 (input 03)
NO Low Analog 01 (input 02)
The respective input is not assigned a function. >FUNCTION E1<

OFF
10.8.2 Digital/analog inputs 02 and 03

Basically, input 02 and input 03 have the same functions as input 01 (see Chapter „Digital input 01“). In addition,
they can also be used as analog inputs. However, the function “Analog 01/02”, which is used to switch over bet-
ween the analog inputs is not available.
In addition, it is possible to configure the contact signals of the inputs as NC or NO.
>FUNCTION E2<
ANALOG 01
The respective input is not assigned a function. bzw.
>FUNCTION E3<
ANALOG 02
10.8.3 Outputs 01 and 02

Each of the outputs 01 and 02 can be assigned one of ten different functions. Optionally, they can also be switched
off.
■■ Ready to run
■■ Collective fault
■■ Collect. signal
■■ Stroke signal
■■ Pre-alarm level
■■ Dry run
■■ Diaphragm rupt. (only with option MBE!)
■■ Batch finished
■■ Internal error
■■ No flow
■■ OFF
In addition, it is possible to configure the contact signals of the outputs as NC or NO. >FUNCTION A1<
Message from the respective output indicating the readiness of the dosing pump. READY TO RUN
Message if one of the following faults occurs:
>FUNCTION A1<
COLLECTING FAULT
■■ Diaphragm rupture
■■ Dry run
■■ Internal error
■■ No flow (with DOSING STOP function)

C/CS 409.2
Message indicating that one of the following faults has occurred: >FUNCTION A1<
COLLECT. SIGNAL
■■ All faults of the collective faults
■■ Pre-alarm level
■■ No flow (with MESSAGE function)
Message from the respective output indicating that a stroke has been performed. >FUNCTION A1<
STROKE SIGNAL
With activated 2-stage level monitoring, message from the respective output indica-
ting a pre-alarm. >FUNCTION A1<
PRE-ALARM LEVEL
With activated level monitoring, message from the respective output indicating the
dry run. >FUNCTION A1<
DRY RUN
With activated diaphragm rupture monitoring, message from the respective output
indicating a diaphragm rupture. (only with MBE option!) >FUNCTION A1<
DIAPHRAGM RUPT.
With activated BATCH operation mode, message from the respective output indica-
ting that the batch is finished. >FUNCTION A1<
BATCH FINISHED
Signal when one of the following listed faults occurs (fault analysis/- causes see chap-
ter „Analysis of the plain text error messages“): >FUNCTION A1<
INTERNAL ERROR
■■ Fault drive
■■ Fault stroke sensor
■■ No stroke recognition
■■ Set value not attained
With activated flow control, message from the respective output indicating that the
>FUNCTION A1<
permitted number of fault strokes has been exceeded.
NO FLOW
10.9 Flow rate indicator
If the dosing pump has not been calibrated, then the flow rate indicator will not be
activated.
NOTE!
The flow rate indicator is activated via the calibration of the pump (see Chapter „Calibration“). The display depends
on the operation mode.
MANUAL operation mode
After calibration of the dosing pump, the flow rate is entered directly as target value in l/h : MANUAL
instead of via the stroke frequency adjustment. In the screen “operating messages” (see 7.2 l/h
Chapter „Screen Operating messages”), the stroke frequency indicator is replaced by the
flow rate indicator. In addition, the total dosing quantity is indicated in litres. : MANUAL
10.34 l
ANALOG operation mode
The calibration of the pump activates the flow rate indicator and the stroke frequency : ANALOG
remains also visible. In addition, the total dosing quantity is indicated in litres. 7.2 l/h
: MANUAL
7.2 l/h

C/CS 409.2
BATCH operation mode
After calibration of the dosing pump, dosing quantity and remaining dosing quantity are : BATCH Man.
indicated in litres. V 10.34 l
: BATCH Man.
R 10.34 l
PULSE operation mode
After calibration of the dosing pump, the total dosing quantity is also indicated in litres. : PULSE
10.34 l
Standard flow rate indicator
With the standard flow rate indicator, the entered target value is converted into the corresponding stroke frequency.
The maximum adjustable target value is limited by the internally determined stroke length.
Example:
The calibration at 50% stroke length results in a flow rate of 10l/h (at 100% stroke frequency). If a target value of 8l/h
is entered, then the stroke frequency is accordingly reduced to 80%.
The maximum target value in this case is 10l/h. It can be changed via the stroke length adjustment (+/- 10%).

Internal calculation:
100% stroke frequency ► Measure in litres: 10l/h
Target value: 8l/h ► 80% stroke frequency
Flow rate indicator with flow meter
The flow meter records the actual value, and if the flow rate deviates from the entered target value, the dosing pump
will readjust it.
If the pump already works with 100% stroke frequency, there is no possibility of
an additional capacity adjust-ment upwards. If the set value is fallen below, the
warning signal “flow too low” appears“.
ATTENTION!
The maximum adjustable target value is limited by the internally determined stroke length.
Example:
The calibration at 50% stroke length results in a delivery rate of 10l/h (at 100% stroke frequency). If a target value of
8l/h is entered, then the stroke frequency is at first accordingly reduced to 80%. The flow meter measures a delivery
rate of 7.9l/h. The internal control increases the stroke frequency to 81% in order to achieve 8l/h.
The maximum target value in this case is 10l/h. It can be changed via the stroke length adjustment (+/- 10%).
Internal control:
100% stroke frequency ► Measure in litres: 10l/h
Target value: 8l/h ► 80% stroke frequency
80% stroke frequency ► Actual value: 7.9l/h
8l/h ► 81% stroke frequency

C/CS 409.2
In order to enable an effective capacity adjustment, pay attention that the given set
value is attained when having a stroke frequency of < 100 %. A max. nominal stro-
ke frequency of approx. 80 % is recommended in order to enable an adjustment of
ATTENTION! the capacity when the set value is fallen below.
The set value in l/h can be preset manually (operating mode MANUAL) or by ana-
log signal (ANALOG) as soon as the dosing pump is calibrated.
NOTE!
10.10 Calibration
The calibration is used to activate the flow rate indicator. Calibration is always done in the same way, no matter
whether a flow meter is connected or not.
Calibration is performed with a fixed stroke length. The calibration remains valid
even if the stroke length is changed by up to +/- 10%. If this calibration range is
exceeded, then the warning message “Out of range” will be displayed:
ATTENTION!
Sequence of calibration:
Prior to the calibration of the flow rate indicator with connected flow meter, the
sensor type (>SENSOR<) must be set (see Chapter „SLOW-MODE“).
If no sensor type is set (OFF), then the calibration will only activate the standard
flow rate indicator.
ATTENTION!
Pay attention to the safety data sheet relating to the dosing medium!
ATTENTION!

C/CS 409.2
■■ Lead the suction line into a calibration pot filled with the dosing medium – the pressure line must be installed in
final position, i.e. the operating conditions (backpressure, etc.) must be fulfilled.
■■ When the suction line is empty the dosing medium must be drawn in (MANUAL operation mode, keep the pump
running).
■■ Set the stroke length with which the pump should be calibrated (can also be done via the manual stroke length
adjustment)
■■ Note the filling level in the calibration pot (= base quantity).
■■ Go to the main menu and select the --CALIBRATION--menu: --CALIBRATION--

PRESS ENTER
■■ Press the ENTER key to access the field for entering the number of calibration
strokes. ENTER
>STROKE NUMBERS<
■■ At first, enter the desired stroke number (at least 200!) ► the higher the stroke 000
number the more accurate the calibration!
preset value
--CALIBRATION--
START with ENTER
■■ To start the calibration, press the ENTER key.
ENTER
■■ The dosing pump performs the preset number of strokes. CALIBRATION . . .

0200
■■ Determination of the pumped quantity execution of strokes...
(= difference between base quantity and remaining quantity in the calibration pot).
CALIBRATION . . .
0000
■■ Entry of the determined quantity. >MEASUREMENT<

00.00 L
preset value
■■ Calibration of the dosing pump is then completed!
DOSING PUMP
calibrated
After the dosing pump has been calibrated, calibration (see Chapter „System“) will
automatically be set to ON.
NOTE!
If the operating conditions are changed (supply line, backpressure, etc.), then the
dosing pump must be newly calibrated. Otherwise, the flow rate indicator might be
inaccurate!
ATTENTION!

C/CS 409.2
10.11 System
The system settings do not depend on the operation mode. These include:
■■ Language
■■ Calibration
■■ Factory reset
■■ System time
>LANGUAGE<
You can select between GERMAN; ENGLISH and SPANISH menu texts.
>CALIBRATION<
The calibration of the pump (see Chapter „Calibration“) can be switched ON and OFF. If the calibration is set to ON
and the dosing pump has been calibrated, then the flow rate indicator is activated.
If the calibration is set to OFF and/or the pump has not been calibrated, then the flow rate indicator is not activated.
>FACTORY RESET<
The factory settings (see Tab. „Overview of preset parameters“, Chapter „Parameter table“) can be restored. To do
so, adjust YES.
After restoring the factory default settings, all previous user-defined settings are
irrevocably overwritten.
ATTENTION!
>SYSTEM TIME<
The system time must be adjusted manually.
If the supply voltage is switched off, then the system time will be reset to 0:00.
This means it must be set again.
ATTENTION!
10.12 Totalizer
The totalizer indicates the total quantity conveyed, the total strokes and the pump’s operating hours. These values are
for information purposes and cannot be reset.
10.13 Password
Two password levels are provided to increase the operating safety of the pump. The passwords for these levels con-
sist of a four-digit number code and are individually selectable.
Password 01 (PW01) is used to protect the setting of the operation mode (Level 01). This password can be activated
and deactivated (when leaving the factory, it is deactivated).
Password 02 (PW02) protects all further setting options of the main menu (Level 02, see “Menu guide”). This pass-
word protection cannot be deactivated.

C/CS 409.2
If, during the 1. password request (Level 01), password 02 has been entered, then
Level 02 is also automatically activated.
NOTE!
The passwords are factory set as follows:
■■ Password 01: 9990 (deactivated)

■■ Password 02: 9021 (cannot be deactivated!)
ATTENTION!
■■ Go to the ---MAIN MENU--- and select the menu item PASSWORD. Setting diagram
---MAINMENU---
PASSWORD
■■ Pressing the ENTER key opens the setting menu for the PW01 mode. ENTER
>PW1-MODE<
OFF
■■ Press the DOWN key to access the setting for Password 01.
>PASSWORD 01<
9990
■■ Value entry for Password 01 is enabled after pressing the ENTER key. ENTER
preset value
■■ After having entered Password 01, press the DOWN key to access the setting for
Password 02.
>PASSWORD 02<
9021
■■ Value entry for Password 02 is enabled after pressing the ENTER key. ENTER
preset value
There is an automatic “Logout” after 5 min of inactivity in the “operation modes”

screen. Afterwards, the password must be entered again.
ATTENTION!
Please write down the passwords and keep them in a safe place. When the pass-
words are lost the pump cannot be configured on site again.
In this case, the pump must be sent to the manufacturer‘s works for configuration
ATTENTION! release.

C/CS 409.2
10.14 Info
The Info menu item contains information about the hardware and software version of the pump.
10.15 Extras
10.15.1 Slow-Mode
In Slow Mode the pump is operated with reduced speed. This is, for example, resona- ---EXTRAS---
ble for the feeding of very viscous media. SLOW-MODE
Adjustments can be made to the following points:
■■ SLOW-MODE
■■ Speed
>SLOW-MODE<
Switching-on/Switching-off of the Slow Mode.
>SPEED<
Input of the speed when Slow Mode is activated. The speed can be set between 100 and 30 %.
The entered speed in Slow Mode corresponds to the maximum stroke frequen-
cy the pump is operated. The maximal possible capacity is reduced correspon-
dingly.
NOTE! The following is valid for the pulse and analog operation: Every stroke is per-
formed with this speed.
10.15.2 Dosing monitoring

The connection of a sera flow controller to the dosing pump will enable the monitoring ---EXTRAS---
of the flow rate. DOSING MONITOR.
The connection of a sera flow meter to the dosing pump will provide a more detailed
flow rate indication with regulation of the flow rate (see Chapter „Flow rate indicator“).
Prior to the calibration of the flow rate indicator with connected flow meter, the
sensor type (>SENSOR<) must be set.
If no sensor type is set (OFF), then the sensor signal will not be considered
ATTENTION! during calibration.
It is possible to make adjustments to following items:
■■ Sensor
■■ Function
■■ Fault stroke
■■ Alarm limit
■■ Calibration

C/CS 409.2
>SENSOR<
Selection of the connected sera flow controller or sera flow meter.
>FUNCTION<
Selection of the dosing monitoring function. It can be selected whether the dosing monitoring should trigger a
warning message (MESSAGE) or a switch-off of the pump (DOSING STOP).
>FAULT STROKE<
Number of fault strokes at which a connected flow controller triggers the dosing monitoring.
The factory setting is 10 fault strokes. This means that the dosing monitoring will react if the flow controller does
not give a stroke confirmation to the pump for the duration of ten consecutive strokes.
>ALARM LIMIT<
Alarm limit at which a connected flow meter triggers the dosing monitoring. The entered value corresponds to the
percental part of the target flow rate.
The factory setting is 80%. This means that the dosing monitoring will react if a connected flow meter measures a
flow rate which is lower than 80% of the set target flow rate.
---CALIBRATION---
see Chapter „Calibration“.
10.15.3 Diaphragm rupture detection (OPTION)

The diaphragm rupture detection (see also Chapter „Diaphragm rupture monitoring ---EXTRAS---
device (option)“) is an optional feature for the dosing pump. It is used to monitor the DIAPHRAGM RUPT.
diaphragm.
■■ Input signal
■■ Sensitivity
>INPUT SIGNAL<
Selection between switch-off (OFF) of the diaphragm rupture electrode and a configuration as NO or NC.
The contact type “switch normally closed” is to be set for conductive media
when using single and double diaphragm pumps. When single diaphragm
pumps are used the diaphragm rupture signalisiation only functions with con-
ductive media. The contact type “switch normally open” is for non-conductive
ATTENTION! media when using double diaphragm pumps with conductive buffer solution.
The setting is ex works.
>SENSITIVITY<
Entry of the sensitivity of the diaphragm rupture electrode in percent. This enables an adaptation to the conduc-
tivity of the pumped medium. In case of poorly conductive media, the sensitivity must be set to a high value (e.g.
100% at approx. 4µS/cm); in case of highly conductive media, the sensitivity must be set to a low value (e.g. 10%
at approx. 50µS/cm).

C/CS 409.2
When leaving the factory, the sensitivity is preset to 50%. This corresponds to
a minimum conductivity of the dosing medium of approx. 10 µS/cm.
The minimum conductivity at 100% sensitivity is 4µS/cm.
NOTE!
10.15.4 Level monitoring

The connection of a sera suction lance enables the monitoring of the filling level in ---EXTRAS---
the dosing tank: LEVEL
■■ Pre-alarm
■■ Dry run
>PRE-ALARM< or >DRY RUN< respectively
Configuration of the two level inputs. It can be selected between either the switch-off (OFF) of the input and a
configuration as NC (opening when floating down) or NO (closing when floating down).
When leaving the factory, both level inputs are configured as NO:
Configuration of the level input

Configuration Pre-alarm Dry run
1 NO NO
2 NO NC
3 NC NC
Configuration 1
When leaving the factory, this configuration is preset. A 1- or 2-stage level monitoring with “closing when floating
down” contacts (pre-alarm and dry run or dry run only) can be connected.
Configuration 2
This configuration must be selected when a 1-stage level monitoring (dry run only) with “opening when floating
down” contact is connected.
Configuration 3
This configuration must be selected when a 2-stage level monitoring with “opening when floating down” contacts
(pre-alarm and dry run) is connected.

C/CS 409.2
10.15.5 Venting automatic (only with CS 409.2)

The self-venting version CS is equipped with a venting automatic (see also Chapter
---EXTRAS---
„Automatic ventilation device CS-design“), which is directly triggered by the control
DE-AERATION
electronics of the dosing pump.
■■ Charge control
■■ Venting time
■■ Interval time
>CONTROL<
Selection of the type of control for triggering the venting. The venting can either be triggered via an external signal
(EXTERNAL), after a preset interval time (INTERVAL), or automatically upon the (re)start of the pump after at least
30 min of inactivity (AUTOMATIC). Optionally, it can also be switched off (OFF).
In addition to the adjustable type of control, a manual venting is also possible

at any time:
Go to the operating message “VENTING: OFF” and press the ENTER key
– then, the venting will be active (“VENTING: ON”) until the ENTER key is
ATTENTION! pressed again respectively the max. Venting time
(5 min) is reached.
: MANUAL
DE-AERATION: OFF
After termination the minimum interval time of 15 min the venting may be star-
ted again.
After pump and suction line have been vented, there might be the possibility
(depending on the backpressure) that small fluid quantities are already conve-
yed into the pressure line although the vent valve is still open.
ATTENTION! The venting period must therefore be coordinated with the possible gas volume
on the suction side of the pump.
In all operating modes of the venting valve the maximum venting time is 5 min
and the minimum interval time is 15 min. If the venting is triggered via an exter-
nal signal pay attention to this designing the external control unit!
NOTE!
>VENTING TIME<
Entry of the venting time in seconds. During each venting procedure, the vent valve will be opened for this time.
The factory setting is 10 sec (range: 5 to 300 sec).

C/CS 409.2
>INTERVAL TIME<
Entry of the interval time (in minutes) at which the venting is repeated (with INTERVAL control). The factory setting
is 40 min (range: 15 to 100 min).
Fig.: „Possible connector pin assignment for external control of the vent valve along with diaphragm rupture message“
RD + BU
PK
GY Diaphragm rupt.
15 V DC
YE
GN Extern ON
BN
Contact signal
WH De-aeration
Contact signal

C/CS 409.2
11. Maintenance
The following safety instructions apply to all service and are sure to follow.
Carry out all maintenance work only on non-pressurized system!
WARNING!
Repairs on the stroke mechanism may only be performed by sera!
WARNING!
Before starting maintenance make sure that the wearing parts and the spare parts
required are available.
Deposit the parts so that they will not get damaged.
WARNING!
All wearing parts are to be checked for prefect condition at regular intervals and ex-
changed if necessary.
WARNING!
Prior to replacing parts from the dosing unit, empty the pump and, if necessary, rinse
it with appropriate fluid in order to avoid contact with aggressive and/or toxic media!
WARNING! Dosing pump with a suitable detergent rinse so that no delivery medium remains in
the pump body. Otherwise, steps out on dismantling pumped. The flushed fluid ab-
sorb contact and disposed of safely!
This measure must also take place before any delivery to a dosing pump repair
purposes.
uring maintenance or repair work, switch off the drive motor of the dosing pump and
D
secure it against inadvertent or unauthorised reactivation!
WARNING!
ake appropriate protective measures:

T
Wear protective clothing, breathing protection and safety goggles. Prepare a contai-
ner with appropriate fluid right beside the pump to be able to remove splashes of the
pumped medium
WARNING!
Check the following at regular intervals:
■■ Check oil level regularly (oil eye)

■■ Tight fit of piping.
■■ Tight fit of pressure and suction valve.
■■ Proper condition of the electrical connections.
■■ Tight fit of the screws for fastening the pump body (check this at least every three months).
For the tightening torques of the mounting screws, please see Chapter „Overview of the tightening torques“.

C/CS 409.2
11.1 Working materials
Pump type Specification sera use Quantity
ARAL
LUBRICANT
CLP VG220 Degol

C/CS 409.2-... DIN51517-3 0,3 Litres
BG220
Quantity
Pump type Type intermediate diaphragm
FPM CSM PTFE PTFE-laminated
C/CS 409.2-4,0 6,5 cm3 6,5 cm3 7,5 cm3 ---
C/CS 409.2-4,0 mit MBE-03 9 cm3 9 cm3 10 cm3 ---
C/CS 409.2-7,0 6,5 cm3 6,5 cm3 7,5 cm3 ---
C/CS 409.2-7,0 mit MBE-03 9 cm3 9 cm3 10 cm3 ---
C/CS 409.2-12 12 cm3 12 cm3 13,5 cm3 ---
C/CS 409.2-12 mit MBE-03 14 cm3 14 cm3 15,5 cm3 ---
C/CS 409.2-18 12 cm3 12 cm3 13,5 cm3 ---
C/CS 409.2-25 12 cm3 12 cm3 13,5 cm3 ---
C 409.2-50 37 cm3 37 cm3 40 cm3 ---

HYDRAULIC FLUID
C 409.2-50 mit MBE-03 37 cm3 37 cm3 40 cm3 ---
C 409.2-75 37 cm3 37 cm3 40 cm3 ---

Glyzerin
DAB87 1)
C 409.2-75 mit MBE-03 37 cm3 37 cm3 40 cm3 ---
C 409.2-90 55 cm3 55 cm3 62 cm3 ---
C 409.2-90 mit MBE-03 55 cm3 55 cm3 62 cm3 ---
C 409.2-115 52 cm3 52 cm3 57 cm3 ---
C 409.2-115 mit MBE-03 52 cm3 52 cm3 57 cm3 ---
C 409.2-140 55 cm3 55 cm3 62 cm3 ---
C 409.2-140 mit MBE-03 55 cm3 55 cm3 62 cm3 ---
C 409.2-180 52 cm3 52 cm3 57 cm3 ---
C 409.2-180 mit MBE-03 52 cm3 52 cm3 57 cm3 ---
C 409.2-250 --- --- --- 240 cm3
C 409.2-250 mit MBE-04 --- --- --- 240 cm3
C 409.2-350 --- --- --- 240 cm3
C 409.2-350 mit MBE-04 --- --- --- 240 cm3
1)
If no other specification is stated in the product description.

C/CS 409.2
11.2 Drive unit
11.2.1 Drive motor

The electric motor should always be kept clean so that neither dust, dirt, oil nor other contaminates may affect the
correct operation.
In addition, we recommend to ensure that:
■■ the motor does not produce strong vibrations

■■ suction and blowing openings for the supply of cooling air are not closed or restricted
(may lead to unnecessary high temperatures in the windings).
The ball bearings inserted in the motor are lubricated for life.
11.2.2 Oil change

■■ Check oil level at regular intervals (oil sight glass (1))
Perform an oil change once a year.

To do so, proceed as follows:
■■ Unscrew the venting screw (5).
■■ Prepare an appropriate container (2). 1
■■ Open the screw plug (3) and drain off oil.
■■ Close hole with screw plug 3

(pay attention to the sealing ring (4)!). 2
4
■■ Fill oil in threaded hole of the venting screw.
■■ For type and quantitiy of the gear oil, please see

5
Chapter “Working materials“.
■■ Screw in venting screw (5).

C/CS 409.2
11.3 Dosing unit
11.3.1 Overview of the tightening torques
3
2
Pump body (2) Pump body (2)

Pump type
without front plate (3) with front plate (3)
Nm
C/CS 409.2-08 e
C/CS 409.2-1,6 e 5,0 4,5

TIGHTENING TORQUES OF THE FIXING SCREWS (1)
C/CS 409.2-2,4 e
C/CS 409.2-4,0 (e)
C/CS 409.2-7,0 (e)
C/CS 409.2-12 (e) 4,0 4,5
C/CS 409.2-18 (e)
C/CS 409.2-25 (e)
C 409.2-50 (e)
C 409.2-75 (e)
C 409.2-90 (e)
7,0 8,0
C 409.2-115 (e)
C 409.2-140 (e)
C 409.2-180 (e)
C 409.2-250 (e)
15,0 15,0
C 409.2-350 (e)

C/CS 409.2
11.3.2 Changing the Diaphragm

In order to ensure a correct function of the diaphragm pump and to fulfil the required safety and protective provisi-
ons it is absolutely necessary to check and replace the diaphragms at regular intervals.
Observe and follow the safety instructions in Chapter 11 „Maintenance“ by all

means.
Man, machine and environment are endangered if the safety instructions are
WARNING! not observed.
For replacing the diaphragm, the system must be depressurised!
WARNING!
11.3.2.1 Single diaphragm pump

■■ Set the stroke length adjustment to a stroke length of
0% (front position).
1
■■ Loosen fixing screws (1) or –nuts on the pump body.
■■ Remove pump body (2) and front plate (if installed) to

the front
2
■■ Screw the drive diaphragm (3) out of the connecting

rod (5). 3
■■ Unscrew pressure plate (4) from the set screw of the

dia-phragm (not with a laminated drive diaphragm). 5
■■ Clean pressure plate and screw plate on the new dia-

phragm.
4
Assemble the pump in reversed order
■■ Set the stroke length to 50%. Move diaphragm (3) to

the base ring (6) – the diaphragm must be in the middle 3
position.
■■ If the pump is not equipped with a stroke length adjust-

ment (M-design), move the diaphragm to the middle
position by turning the fan blade of the drive motor.
■■ When assembling the pump body, please note:suction 6

valve below, pressure valve above!
Add the suction and pressure line and connect pump to the power supply. The diaphragm pump is then again
ready for operation.

C/CS 409.2
11.3.2.2 Double diaphragm pump

■■ Drain buffer fluid (8) (by opening the screw plug).
3 7
■■ Loosen fixing screws (1) on the pump body (2) and re- 1
move intermediate diaphragm (7).
■■ Remove the diaphragm ring (9) to the front if the drive 2

diaphragm (3) is to be replaced, too.
8
Assemble the pump in reversed order
■■ Installation of the drive diaphragm (see Chapter „Single

diaphragm pump“ (Changing the Diaphragm)).
■■ Insert intermediate diaphragm (7) in the diaphragm

ring (9) (in case of a PTFE-laminated intermediate dia- 8 10
phragm the PTFE-coated side must point towards the
pump body (2)).
■■ When assembling the pump body, please note: suction

valve (11) below, pressure valve (10) above! 7 2
■■ Observe the tightening torques (see Chapter „Overview

of the tightening torques“).
■■ Set the stroke length to 100%. If the pump is not equip-

ped with a stroke length adjustment (M-design), move
the diaphragm to the rear position by turning the fan 11
9
blade of the drive motor.
■■ Fill buffer fluid (8) in the diaphragm ring (type and

quantity are indicated on the type plate).
12
■■ If the dosing pump has a small conveying capacity the

buffer fluid (8) is to be filled in with a disposable syrin-
ge (12).
■■ Venting the buffer fluid chamber:

wait for appr. 2 minutes after filling in until the air dis-
8
solved in the buffer fluid has outgassed.

C/CS 409.2
■■ Move the drive diaphragm (3) to the front by turning the
stroke length adjustment (in clockwise direction) until 13
the buffer fluid (8) level has reched the top edge of the
filling hole(s).
■■ Screw in the screw plug(s) (13).
■■ Reset the stroke length to the initial value.

3
Add the suction and pressure line and connect pump to the 8
power supply. The diaphragm pump is then again ready for
operation.
11.3.2.3 Overflow valve

Proceed as follows to change the diaphragm of the overflow valve (only dosing pumps with integrated overflow
valve).
All diaphragms should be replaced completely.
NOTE!
Loosen and unscrew the lid (1) of the overflow valve.

C/CS 409.2
Before the set screw is unscrewed the dimension T (dis-tance between top
edge of the cover and the set screw) is to be determined and documented.
This ensures that the overflow valve can be reset to the same pressure
during subsequent assembly.
NOTE!
T
?? ? ? ? ? ? ? ? ? ? ?
?????? ?? ?? ?? ?? ?? ?? ?? ?
■■ Unscrew the set screw (3).
2 3
■■ Remove pressure spring (2).
5
■■ Loosen and unscrew fixing screws (5).
■■ Remove cover (7) and pump body (8) 4

to the front.
7
■■ Remove pressure disk (4) and dia-
phragm (6). 6
■■ Check overflow valve for damage and contamination.
■■ Insert a new diaphragm. In case of PTFE-laminated diaphragms the PTFE-coated side must point to-
wards the pump body.
■■ Assemble the pump in reversed order.

C/CS 409.2
The individual components should be cleaned thoroughly before assembly!
NOTE!
When the set nut is screwed in the dimension “T” which was determined
beforehand is of great importance.
The initial opening pressure of the overflow valve is only reached when the
NOTE! set screw is screwed in exactly according to dimension “T”!
The screw-in depth of the set screw must not exceed the initial value. If the
set pressure is increased, sera has to be consulted beforehand!
ATTENTION!
Never screw in the set screw to a depth so that the pres-sure spring is com-
pressed to solid length!
ATTENTION!
12. Spare and wearing parts
12.1 Wearing parts

The following parts are considered as wearing parts of the diaphragm pump:
■■ Drive diaphragm
■■ Intermediate diaphragm (only for double diaphragm pump)
■■ Diaphragm of the integrated overflow valve (if installed)
■■ Suction valve
■■ Pressure valve
Depending on their use and period of use, wearing parts must be replaced at regular intervals in order to ensure a
safe function of the diaphragm pump.
We recommend to replace the wearing parts after 3000 operating hours or at least once a year.
In case of a premature diaphragm rupture caused by hard operating conditions, switch off the diaphragm pump and
replace the diaphragms (see Chapter „Changing the diaphragm“).
As an option, the diaphragm pump can be equipped with a diaphragm rupture monitoring device MBE-… (please see
Chapter “Diaphragm rupture monitoring device “ (Functional description)).
12.2 Spare parts

The following parts are considered as spare parts of the diaphragm pump:
■■ Pump body
■■ Diaphragm ring (only for double diaphragm pump)
■■ Automatic ventilation device (CS 409.2)

C/CS 409.2
12.3 Spare and wearing parts
12.3.1 Diaphragm pump C 409.2- 0,8 e ...-2,4 e
C409.2 - 0,8 e
C409.2 - 1,6 e
C409.2 - 2,4 e
4
2
5 8
Overview of the spare and wearing part kits

Diaphragm pump C 409.2- 0,8 e ...-2,4 e
Suction valve (kit) Pump body kit (plastic, FRP-design)

Pos. consisting of Pos. consisting of
8 Suction valve (incl. o-rings) 1 Vent valve
2 Screws, complete
Pressure valve (kit) 3 Pump body
Pos. consisting of
4 Pressure valve (incl. o-rings) Pump body kit (plastic)
Pos. consisting of
Diaphragm kit 5 Screws, complete
Pos. consisting of 6 Front plate
9 Drive diaphragm 7 Pump body

C/CS 409.2
C409.2 - 4,0 (e)

C409.2 - 7,0 (e)
C409.2 - 12 (e)
C409.2 - 18 (e)
C409.2 - 25 (e)
C409.2 - 50 (e)
C409.2 - 75 (e)
C409.2 - 90 (e)
C409.2 - 115 (e)
C409.2 - 140 (e)
C409.2 - 180 (e)
3 5 13
2 12
11
10
8
1
7
9
6

C/CS 409.2

Diaphragm pump C 409.2- 4,0 (e) ...-180 (e)
Suction valve (kit) Pump body kit (plastic, FRP-design)

9 Suction valve (incl. o-rings) 1 Cover plate
2 Screws, complete
Pressure valve (kit) 3 Insertion plate(s), if applicable
Pos. consisting of 4 Pump body
5 Pressure valve (incl. o-rings)
Pump body kit (plastic)
Diaphragm kit (single diaphragm pump) Pos. consisting of
Pos. consisting of 6 Screws, complete
12 Drive diaphragm 7 Front plate
13 Pressure plate 8 Pump body
(not with a laminated drive diaphragm)
Pump body kit (special steel)
Diaphragm kit (double diaphragm pump) Pos. consisting of
10 Intermediate diaphragm 8 Pump body
12 Drive diaphragm
13 Pressure plate
Buffer fluid
Diaphragm ring kit (only for double diaphragm pump)

Pos. consisting of
11 Diaphragm ring, complete

C/CS 409.2
C409.2 - 250 (e)

C409.2 - 350 (e)
7
3
2 6

C/CS 409.2

Diaphragm pump C 409.2-250 (e) ...-350 (e)
Suction valve (kit) Pump body kit (plastic)

5 Suction valve (incl. o-rings) 1 Screws, complete
2 Front plate
Pos. consisting of
4 Pressure valve (incl. o-rings) Pump body kit (special steel)
Pos. consisting of
Diaphragm kit (single diaphragm pump) 1 Screws, complete
8 Drive diaphragm
Diaphragm kit (double diaphragm pump)

Pos. consisting of
6 Intermediate diaphragm
8 Drive diaphragm
Buffer fluid

Pos. consisting of

C/CS 409.2

with integrated overflow valve
C409.2 - 4,0 (e)

C409.2 - 7,0 (e)
C409.2 - 12 (e)
C409.2 - 18 (e)
C409.2 - 25 (e)
C409.2 - 50 (e)
C409.2 - 75 (e)
C409.2 - 90 (e)
C409.2 - 115 (e)
C409.2 - 140 (e)
C409.2 - 180 (e)
4
3
12
14
11 15
9 10 16
8
7 13
6 17
5

C/CS 409.2

Diaphragm pump C 409.2- 4,0 (e) ...-180 (e) with integrated overflow valve
Suction valve (kit) Overflow valve (kit)

13 Suction valve (incl. o-rings) 6 Lid
7 Set screw
Pressure valve (kit) 8 Pressure spring
Pos. consisting of 9 Cover
12 Pressure valve (incl. o-rings) 10 Pressure disk
Diaphragm kit (single diaphragm pump) Pump body kit (plastic)

3 Drive diaphragm 5 Screws, complete
(not with a laminated drive diaphragm) 17 O-ring
11 Diaphragm (overflow valve)
Pump body kit (special steel)
3 Drive diaphragm 15 O-ring
4 Pressure plate 16 Socket
Buffer fluid

Pos. consisting of

C/CS 409.2

C409.2 - 250 (e)

C409.2 - 350 (e)
3
2
18
16
19
15
17
5
12 14 20
11 13
10
4 9

C/CS 409.2

Diaphragm pump C 409.2-250 (e) ...-350 (e) with integrated overflow valve

10 Set screw
Pos. consisting of 12 Pressure spring
8 Pressure valve (incl. o-rings) 13 Hexagon screw(s)
14 Disk(s)
Diaphragm kit (single diaphragm pump) 15 Cover
Pos. consisting of 16 Pressure disk
3 Drive diaphragm
6 Diaphragm (overflow valve) Pump body kit (plastic)
Pos. consisting of
Diaphragm kit (double diaphragm pump) 4 Screws, complete
Pos. consisting of 5 Front plate
3 Drive diaphragm 20 O-ring
Buffer fluid Pump body kit (special steel)
Pos. consisting of
Diaphragm ring kit (only for double diaphragm pump) 4 Screws, complete
2 Diaphragm ring, complete 18 O-ring
19 Socket
20 O-ring

C/CS 409.2
12.3.6 Diaphragm pump CS 409.2- 0,8 e ...-2,4 e
CS409.2 - 0,8 e
CS409.2 - 1,6 e
CS409.2 - 2,4 e
6
3

C/CS 409.2

Diaphragm pump CS 409.2- 0,8 e ...-2,4 e
Suction valve (kit) Pump body kit (plastic)

6 Suction valve (incl. o-rings) 3 Screws, complete
4 Front plate
Pos. consisting of
2 Pressure valve (incl. o-rings) Automatic ventilation device -kit
Pos. consisting of
Diaphragm kit 1 Automatic ventilation device (incl. o-ring)
Pos. consisting of
7 Drive diaphragm

C/CS 409.2
CS409.2 - 4,0 (e)

CS409.2 - 7,0 (e)
CS409.2 - 12 (e)
CS409.2 - 18 (e)
CS409.2 - 25 (e)
1
4 12
11
10
9
7
6
8
5

C/CS 409.2

Diaphragm pump CS 409.2- 4,0 (e) ...-25 (e)
Suction valve (kit) Pump body kit (FRP-design)

8 Suction valve (incl. o-rings) 5 Cover plate
6 Screws, complete
Pos. consisting of
4 Pressure valve (incl. o-rings) Pumpenkörper-Set (PVC)
Pos. consisting of
Diaphragm kit (single diaphragm pump) 1 Screws, complete
11 Drive diaphragm
12 Pressure plate Entlüftungsautomatik-Set
(not with a laminated drive diaphragm) Pos. consisting of
3 Automatic ventilation device (incl. o-ring)
Diaphragm kit (double diaphragm pump)
Pos. consisting of
11 Drive diaphragm
12 Pressure plate
Buffer fluid

Pos. consisting of

C/CS 409.2

CS409.2 - 4,0 (e)

CS409.2 - 7,0 (e)
CS409.2 - 12 (e)
CS409.2 - 18 (e)
CS409.2 - 25 (e)
15 17
16
14
7 11
13
6
5
12
4
3 10
2

C/CS 409.2

Diaphragm pump CS 409.2- 4,0 (e) ...-25 (e) with integrated overflow valve

3 Set screw
Pos. consisting of 5 Cover
8 Pressure valve (incl. o-rings) 6 Pressure disk
Diaphragm kit (single diaphragm pump) Pump body kit (plastic)

15 Drive diaphragm 1 Screws, complete
Automatic ventilation device -kit
Pos. consisting of 9 Automatic ventilation device (incl. o-ring)
15 Drive diaphragm
16 Pressure plate
Buffer fluid

Pos. consisting of

C/CS 409.2
13. Fault analysis and corrective action

sera products are sophisticated technical products which are only shipped after having been thoroughly tested and che-
cked at our factory.
Should there be any faults, these can be – on account of fault announcement on LCD-display – detected and rectified
easily and quickly if the steps in Tables are carried out.
13.1 Analysis of the plain text error messages
Error message Possible cause Corrective action

Cycle-delay memory full!
Analog signal > 20 mA!
No stroke recognition!
Analog signal < 4 mA!
Leave the calibration
(internal fault)
Flow too low!
No flow!
range!
Check analog signal line and repair, if

█ Wire break of the analog signal line.
necessary.
The set analog signal (e.g. 4-20mA)

Check the set analog signal and adapt to
█ does not match the actual analog signal
the actual analog signal, if necessary.
(e.g. 0-20mA).
Fault of the analog signal transmitter Check the analog signal transmitter and eli-
█ █ █ (sensor, controller). minate fault of the transmitter if necessary.
█ █ Drive diaphragm defective. Replace drive diaphragm.
Reduce suction height or suction resi-

█ █ Suction height too high.
stance.
█ █ Suction line leaky. Check gaskets, tighten pipe connections.
Open shut-off valves or check opening –

█ █ Shut-off valves in pipe closed.
check pump for damage.
Few or no conveying medium in store

█ █ tank.
Fill store tank.
█ █ Pump valves leaky. Remove valves and clean.
Foreign matter in pump valves or Pump Remove and clean valves, check function;
█ █ valves (ball seats) damaged. replace valves if necessary.
Check installation position and comple-

Pump valves incorrectly mounted or
█ █ valve balls missing.
teness – replace missing parts or install
correctly.
█ █ Filter in suction line clogged. Clean filter.
No stroke movement of the drive dia- Increase stroke frequency / stroke length;
█ █ phragm. check connecting rod motion.
Measure pressure with manometer directly

█ █ Counter-pressure too high. above pressure valve and compare with
permissible counter-pressure.
Check acceleration height on suction- and

Acceleration height too high due to pipe pressure side and compare with design
█ █ geometry. data – install a pulsation damper if neces-
sary.
Check viscosity of the pumped medium

Too high viscosity of the pumped and compare with the design data – reduce
█ █ medium. concentration or increase temperature if
necessary.

C/CS 409.2
Cycle-delay memory full!

No stroke recognition!
Analog signal < 4 mA!
Leave the calibration
(internal fault)
Flow too low!
No flow!
range!
Check geodetic conditions and compare

Pumped medium outgasses in suction with the data of the pumped medium. Ope-
█ █ line and/or pump body. rate pump with suction side supply, reduce
temperature of the pumped medium.
Vent pressure side resp. open vent valve

Air in suction line while pressure applied
█ █ to the pressure valve ball.
(only FRP-design, see chap. „Manual vent
valve“ (Functional description)).
Tighten connection according to type of

█ █ Pipe connections leaky. material. Be careful with plastic – risk of
fracture
Remove diaphragm pump and check for

█ █ Pumped medium frozen in pipe. damage – increase temperature of the
pumped medium.
Moisten pump body and valves.

█ █ Pump valves are dry.
Open vent valve.
Frequency of the received pulses is

█ (permanently) higher than the maximum Check process parameters.
stroke frequency of the dosing pump.
█ Pulse factor too high. Check process parameters.
After calibration of the dosing pump the Check the stroke length adjustment, set
█ stroke length was adjusted by more than the set value again, calibrate again, if
+/- 10%. necessary.
Stroke length was set to below 15%

Check the stroke length adjustment, incre-
█ approx., the stroke length is out of the
ase the stroke length.
linear dosing range.
Sensory mechanism of dosing pump is

█ defective.
Contact the manufacturer.

C/CS 409.2
Fault drive! (Internal fault!)

Set value not attainable!
Mains voltage too g too
Mains voltage too high!
Dry running of dosing

Fault stroke sensor!!
Diaphragm rupture!
(Internal fault!!)
Pre-alarm level!
(Internal fault!!)
pump!
low!
█ Drive diaphragm defective. Replace drive diaphragm.
Electric data of the dosing pump do not Check order data.

█ █ match mains data. Check electric installation.
Few or no conveying medium in store

█ █ tank.
Fill store tank.
Only for calibrated pump: Set stroke

Check the stroke length and the set value,
█ length is too low to attain the preset set
calibrate the pump again, if necessary.
value.
Integrated excess temperature protection Let the temperature of the drive motor go
█ (posistor) of drive motor released. down. Check the ambient temperature.
No stroke movement of the drive dia- Increase stroke frequency / stroke length;
█ phragm. check connecting rod motion.

█ Counter-pressure too high. above pressure valve and compare with

█ Shut-off valves in pipe closed.
13.2 Analysis of other faults
Type of fault Possible cause Fault clearance

Low service life of the drive diaphragm
Damage in stroke mechanism / drive

Diaphragm pump does not draw in
Diaphragm pump does not deliver
Maximum delivery rate exceeded

Delivery height is not reached
Delivery rate is not reached
Drive motor does not start
High noise development
Leakage on pump head

Delivery rate fluctuates
Pipe oscillates heavily
Drive is overloaded
Reduce suction height or suction resi-

█ █ █ Suction height too high.
stance.
█ █ █ █ Suction line leaky. Check gaskets, tighten pipe connections.

█ █ █ █ Shut-off valves in pipe closed.
No conveying medium in store

█ █ █ tank.
Fill store tank.
█ █ █ █ █ Pump valves leaky. Remove valves and clean.

C/CS 409.2
Type of fault Possible cause Fault clearance
Damage in stroke mechanism / drive

Diaphragm pump does not draw in
Diaphragm pump does not deliver
Maximum delivery rate exceeded
Low service life of the drive dia-

Delivery height is not reached
Delivery rate is not reached
Drive motor does not start
High noise development
Leakage on pump head

Delivery rate fluctuates
Pipe oscillates heavily
Drive is overloaded
phragm
Pump valves (ball seats) dama- Remove and clean valves, check function;
█ █ █ █ ged. replace valves if necessary.
Check installation position and comple-

Pump valves incorrectly mounted
█ █ or valve balls missing.
teness – replace missing parts or install
correctly.
█ █ Filter in suction line clogged. Clean filter.
Electric data of the electronics do Check order data. Check electric installa-
█ █ not match mains data. tion.

█ █ █ █ █ █ █ █ █ Counter-pressure too high. above pressure valve and compare with
█ █ █ █ █ Foreign matter in pump valves. Remove and clean valves.
Pressure on suction side higher

Check geodetic conditions, install float val-
█ █ than at the end of the pressure
ve or pressure keeping valve if necessary.
line.
Check acceleration height on suction- and

Acceleration height too high due pressure side with manometer and com-
█ █ █ █ █ █ █ █ █ █ █ to pipe geometry. pare with design data – install a pulsation
damper if necessary.
Material which is in contact with Check whether the pumped medium cor-
█ █ the medium not suitable for the responds with the design data and select
pumped medium. other materials if necessary.
Check viscosity of the pumped medium

Too high viscosity of the pumped and compare with the design data – reduce
█ █ █ █ medium. concentration or increase temperature if
necessary.
Check geodetic conditions and compare

Pumped medium outgasses in with the data of the pumped medium. Ope-
█ █ █ suction line. rate pump with suction side supply, reduce
temperature of the pumped medium.
Air in suction line while pressure Vent pressure side resp. open vent valve
█ ap-plied to the pressure valve ball. (only FRP-design C409.2-0,8e- …2,4e).
Tighten connection according to type of

█ █ █ █ █ █ Pipe connections leaky. material. Be care-ful with plastic – risk of
fracture.
Check flowability of the pumped medium.

█ █ █ █ Temperature too low. Temperature of pumped medium and ambi-
ent temperature must not fall below -10°C.
Remove diaphragm pump and check for

█ █ █ █ █ Pumped medium frozen in pipe. damage – in-crease temperature of the
pumped medium.
Replace diaphragm according to Chapter

█ █ █ █ █ █ █ Diaphragm rupture.
„Changing the Diaphragm“.

C/CS 409.2
14. Shut-down
■■ Switch off piston diaphragm pump.
■■ Rinse pump head and remove pumped medium; make sure that the rinsing agent is suitable for pumped medium
and pump head.
15. Disposal
■■ Shut-down system. Please see “Shut-down“.
15.1 Dismantling and transport

■■ Shut-down system. Please see “Shut-down“.
■■ Remove all fluid residues from pump body, clean thoroughly, neutralize and decontaminate.
■■ Package unit and ship.
A clearance certificate must be filled in when systems are returned to the manuf-
acturer (see Chapter 16).
Acceptance will be rejected if this clearance certificate is not attached.

NOTE!
The consignor is responsible for leaking lubricants or

fluids!
WARNING!
15.2 Complete disposal

■■ Remove all fluid residues from unit.
■■ Drain off lubricants and dispose of according to regulations!
■■ Dismount materials and send them to a suitable waste disposal company!
The consignor is responsible for leaking lubricants or fluids!
WARNING!

C/CS 409.2
16. Clearance Certificate
Inspection / repair of machines and machine parts is only carried out after the op-
posite clearance certificate was filled in correctly and completely by authorized and
qualified personnel.
NOTE!
Acceptance will be refused if parts are returned to the manufacturer without a proper
clearance certificate.
NOTE!
All industrial companies are obligated by the legal provisions for occupational health, e.g. the workplaces ordinances,
the Ordinance on Hazardous Substances, the regulations for prevention of accidents and the environmental protection
regulations such as the Waste Management Act and the German Household Water Act to protect their employees or
man and the environment from detrimental effects when handling hazardous substances.
Should special safety precautions be necessary despite careful draining and cleaning of the product
the necessary information are to be provided.
Machines which are operated with radioactive media shall only be inspected and/or repaired in the
safety area of the owner by a sera specialized fitter.
The clearance certificate is part of the inspection-/repair order.

sera reserves the right to refuse acceptance of the order for other reasons.
Please make a copy and leave the original with the operating instructions!
(can also be downloaded from: www.sera-web.com)
NOTE!

C/CS 409.2
Clearance Certificate
Product
Type Serial-No.
the product was carefully emptied before shipping / delivery, and cleaned inside and outside. □ YES
Conveying medium
Designation Concentration %
Properties
□ □ □ □ □
Toxic Corrosive Flammable Oxidising Unhealthy
Please tick!
□
If either of the listed properties, Harmless
then enclose the appropriate
safety and handling instruc- □ □ □ □ □
□ tions. Explosive Dangerous for
the environment
Irritant Bio-
hazardous
Radioactive
The product was used with health or water-polluting substances and came up with labeling □ YES
requirements and pollution prone media in contact.
□ NO
Special security arrangements with respect to health or water-hazardous media □ not required
are in the further handling
□ required
The following safety precautions regarding rinsing, residual liquids and waste disposal are required:
Process data
The product was used with the following operating conditions described conveying medium:
Temperature °C Pressure bar
Sender
Company: Telephone:
Contact person: FAX:
Address: E-mail:
Zip code, City: Your order No:

We confirm that we have the information in this safety certificate (Clearance Certificate) have been correctly and
completely and that the returned parts were carefully cleaned.
QSF 469-01 en / 11.2014 / PM
The parts are sent free of residues of dangerous amount.
Place, Date Department Signature

(and company stamp)
www.sera-web.com 1

C/CS 409.2
NOTES

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2 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 3

4 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 5

Q.1 Power connection

The CS 409.2 is available in three versions:

Only operate the pump when it is connected to an earthed power supply!

6 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

Q.2 Control elements

Q.3 LED operation indicators

Green: Operation and stroke indicator

Yellow: Warning indicator

Red: Fault indicator

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 7

Q.5 Factory settings

8 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

Q.6 Control inputs and outputs

Q.6.1 Control via contact signal

GY Collecting Fault (15V DC) +

Q.6.2 Control via analog signal

Control cabinet customer

GY Output 01 Collecting fault max. 50 mA +

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 9

Proceed as follows to select the operating mode:

PW01 Locking by password 01 (pre setting ex work: 9990, not activated)

10 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

1.1 General user information

1.2 Symbols and notes used in these operating instructions

Designation of the note Danger type Definition of the note

(Text and symbol) (in the operating instructions)

Identifies an imminent danger

Designates a potentially dangerous situation

Designates a potentially dangerous situation

Designates a potentially dangerous situation

Designates information which helps to make work

1.3 Notes attached to the product

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 11

1.4 Quality instructions

■■ avoid dangers to persons, machines and environment.

2.1 Personnel qualification and training

2.2 Dangers in case of inobservance of the safety instructions

■■ Failure of important functions of the product/system.

2.3 Safety conscious working

12 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

2.4 Safety instructions for owner / operator

Danger caused by electrical energy is to be avoided.

2.5 Safety instructions for maintenance, servicing and installation work

2.6 Arbitrary modification and production of spare parts

2.7 Improper operations

2.8 Intended use

TA 414 Rev. 11 en 06/2016 Subject to technical modifications! www.sera-web.com 13

2.9 Operating conditions

2.10 Personal protection for maintenance and service

In case of accidents check whether the following substances are emitted:

Emissions are to be monitored by corresponding controly systems of the total installation.

Personal protective equipment must be provided by the owner!

14 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016

2.11 Foreseeable misuse

Misuse can result in danger to the operating personnel!

2.11.2 Assembly and installation

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2.11.5 Maintenance / Repair

16 www.sera-web.com Subject to technical modifications! TA 414 Rev. 11 en 06/2016